New Holland Tn55 Tn65 Tn70 Tn75 Workshop Manual

SECTION 00 -- GENERAL -- CHAPTER 1 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.
BATTERY
Before carrying out any kind of service operations, disconnect and isolate the battery negative lead, unless other-
wise requested for specific operations (e.g.: operations that require the engine running). Once the specific oper-
ation has been completed, disconnect the lead in order to complete the operation.
SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add
up the recorder values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated
value indicated for each on shim.
ROTATING SHAFT SEALS

For correct rotating shaft seal installation, proceed as follows:
-- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes;
-- thoroughly clean the shaft and check that the working surface on the shaft is not damaged;
-- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc-
tion and position the grooves so that they will deviate the fluid towards the inner side of the seal;
-- coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing
lip and the dust lip on double lip seals with grease;
-- insert the seal in its seat and press down using a flat punch, do not tap the seal with a hammer or mallet;
-- whilst inserting the seal, check that the it is perpendicular to the seat; once settled, make sure that it makes
contact with the thrust element, if required;
-- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
O--RING SEALS
Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist-
ing, which would jeopardise sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces marked with an X: LOCTITE 518, LOC-
TITE 5205, SUPERBOND 559 MASCHERPA or BETABLOCK A272M GURIT ESSEX.
Before applying the sealing compound, prepare the surfaces as follows:
-- remove any incrustations using a metal brush;
-- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a
water and soda solution.
BEARINGS
When installing bearings it is advised to:
-- heat the bearings to 80 to 90 °C (176 to 194 °F) before fitting on the shafts;
-- allow the bearings to cool before installing them from the outside.
SPRING PINS
When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required
to stress the pin.
Spiral spring pins do not require special positioning.
2 SECTION 00 -- GENERAL -- CHAPTER 1
SPARE PARTS
Only use original NEW HOLLAND spare parts bearing the logo shown below.
1
Only original spare parts guarantee the same quality, duration and safety as they are the same parts that are
assembled during production.
Only original NEW HOLLAND parts can offer this guarantee.
When ordering spare parts, always provide the following information:
-- tractor model (commercial name) and frame number;
-- engine type and number;
-- part number of the ordered part, which can be found in the ”Microfiches” or the ”Spare Parts Catalogue”, used
for order processing.
TOOLS
The tools that NEW HOLLAND propose and illustrate in this manual are:
-- specifically researched and designed for use with NEW HOLLAND tractors;
-- essential for reliable repair operations;
-- accurately built and rigorously tested so as to offer efficient and long--lasting operation.
By using these tools, Repair Personnel will benefit from:
-- operating in optimal technical conditions;
-- obtaining the best results;
-- saving time and effort;
-- working in safe conditions.
NOTE
Wear limit values indicated for certain parts are recommended, but not binding. The terms ”front”, ”rear”, ”right--
hand” and ”left--hand” (when referred to different parts) are intended as seen from the driving position with the
tractor in the normal direction of movement.
MOVING THE TRACTOR WITH THE BATTERY REMOVED

External power supply cables should only be connected to the respective positive and negative cable terminals,
using efficient clamps that guarantee adequate and secure contact.
Disconnect all services (lights, windshield wipers, etc.) before starting the tractor.
If the tractor electrical system requires checking, carry out operations with the power supply connected. Once
checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
SAFETY REGULATIONS
WARNING AND DANGER SYMBOL
This warning symbol points out important messages
concerning your safety.
Carefully read the following safety regulations and
observe advised precautions in order to avoid poten-
tial hazards and safeguard your health and safety.
In this manual the symbol is accompanied by the fol-
lowing key--words:
WARNING -- Warnings concerning unsuitable repair
operations that may jeopardise the safety of Repair
personnel.
DANGER -- Specific warnings concerning potential
hazards for operator safety or for other persons di-
rectly or indirectly involved. 2
-- Do not carry out repair operations with someone
sitting in the driver’s seat, unless the person is a
ACCIDENT PREVENTION trained technician who is assisting with the oper-
ation in question.
Most accidents or injuries that occur in workshops
are the result of non--observance of simple and fun- -- Do not operate the machine or use any of the im-
damental safety regulations. For this reason, IN plements from different positions, other than the
MOST CASES THESE ACCIDENTS CAN BE driver’s seat.
AVOIDED by foreseeing possible causes and conse- -- Do not carry out operations on the machine with
quently acting with the necessary caution and care. the engine running, unless specifically indicated.
Accidents may occur with all types of machine, re-
-- Stop the engine and check that the hydraulic cir-
gardless of how well the machine in question was de-
cuits are pressure--free before removing caps,
signed and built.
covers, valves, etc.
A careful and judicious service technician is the best
guarantee against accidents. -- All repair and maintenance operations must be
carried out using extreme care and attention.
Precise observance of the most basic safety rule is
normally sufficient to avoid many serious accidents. -- Service steps and platforms used in the work-
shop or elsewhere should be built according to
DANGER. Never carry out any cleaning, lubrication
standard accident prevention regulations.
or maintenance operations when the engine is run-
ning. -- Disconnect the batteries and label all controls to
indicate that the tractor is being serviced. Any
parts that are to be raises must be locked in posi-
tion.
SAFETY REGULATIONS
-- Do not check or fill fuel tanks, accumulator bat-
teries, nor use starting liquid when smoking or
near naked flames, as these fluids are inflam-
GENERAL GUIDELINES mable.
-- Carefully follow specified repair and mainten- -- Brakes are inoperative when manually released
ance procedures. for repair or maintenance purposes. Use blocks
-- Do not wear rings, wristwatches, jewellery, un- or similar devices to control the machine in these
buttoned or loose articles of clothing such as: conditions.
ties, torn clothing, scarves, open jackets or shirts -- The fuel nozzle should always be in contact with
with open zips that may remain entangled in the filling aperture. Maintain this position until fill-
moving parts. It is advised to wear approved ing operations are completed in order to avoid
safety clothing, e.g.: non--slip footwear, gloves, possible sparks caused by the accumulation of
safety goggles, helmets, etc. static electricity.
-- Only use specified towing points for towing the -- If operating outside the workshop, position the
tractor. Connect parts carefully. Make sure that tractor on a flat surface and lock in position. If
all pins and/or locks are secured in position be- working on a slope, lock the tractor in position.
fore applying traction. Never remain near the Move to a flat area as soon as is safely possible.
towing bars, cables or chains that are operating -- Damaged or bent chains or cables are unreliable.
under load. Do not use them for lifting or towing. Always use
-- Transport tractors that cannot be driven using a suitable protective gloves when handling chains
trailer or a low--loading platform trolley, if avail- or cables.
able. -- Chains should always be safely secured. Make
-- When loading or unloading the tractor from the sure that the hitch--up point is capable of sustain-
trailer (or other means of transport), select a flat ing the load in question. Keep the area near the
area capable of sustaining the trailer or truck hitch--up point, chains or cables free of all by-
wheels. Firmly secure the tractor to the truck or standers.
trailer and lock the wheels in the position used by -- Maintenance and repair operations must be car-
the carrier. ried out in a CLEAN and DRY area. Eliminate any
-- Electric heaters, battery--chargers and similar water or oil spillage immediately.
equipment must only be powered by auxiliary -- Do not create piles of oil or grease--soaked rags
power supplies with efficient ground insulation to as they represent a serious fire hazard. Always
avoid electrical shock hazards. store rags in a closed metal container.
-- Always use suitable hoisting or lifting devices Before starting the tractor or implements, make
when raising or moving heavy parts. sure that the driver’s seat is locked in position.
-- Take extra care if bystanders are present. Also check that there are no persons within the
tractor or implement range of action.
-- Never pour gasoline or diesel oil into open, wide
or low containers. -- Empty pockets of all objects that may fall unob-
served into the tractor parts.
-- Never use gasoline, diesel oil or other inflam-
mable liquids as cleaning agents. Use non--in- -- In the presence of protruding metal parts, use
flammable, non toxic commercially available sol- protective goggles or goggles with side guards,
vents. helmets, special footwear and gloves.
-- Wear safety goggles with side guards when -- When welding, use protective safety devices:
cleaning parts with compressed air. tinted safety goggles, helmets, special overalls,
gloves and footwear. All persons present in the
-- Limit the air pressure to a maximum of 2.1 bar (31
area where welding is taking place must wear
PSI), according to local regulations.
tinted goggles. NEVER LOOK DIRECTLY AT
-- Do not run the engine in confined spaces without THE WELDING ARC WITHOUT SUITABLE
suitable ventilation. EYE PROTECTION.
-- Do not smoke, use naked flames, or cause -- Metal cables tend to fray with repeated use. Al-
sparks in the area when fuel filling or handling ways use suitable protective devices (gloves,
highly inflammable liquids. goggles, etc.) when handling cables.
-- Never use naked flames for lighting when work- -- Handle all parts carefully. Do not put your hands
ing on the machine or checking for leaks. or fingers between moving parts. Wear suitable
-- All movements must be carried out carefully safety clothing -- safety goggles, gloves and
when working under, on or near the tractor. Wear shoes.
protective equipment: helmets, goggles and
special footwear.
-- When carrying out checks with the engine run-
ning, request the assistance of an operator in the
driver’s seat. The operator must maintain visual
contact with the service technician at all times.
START UP HYDRAULIC SYSTEMS

-- Never run the engine in confined spaces that are -- A liquid leaking from a tiny hole may be almost
not equipped with adequate ventilation for ex- invisible but, at the same time, be powerful
haust gas extraction. enough to penetrate the skin. Therefore, NEVER
USE HANDS TO CHECK FOR LEAKS but use
-- Never place the head, body, limbs, feet, hands or
a piece of cardboard or wood for this purpose. If
fingers near fans or rotating belts.
any liquid penetrates skin tissue, call for medical
aid immediately. Failure to treat this condition
ENGINE with correct medical procedure may result in seri-
-- Always loosen the radiator cap slowly before re- ous infection or dermatosis.
moving it to allow any remaining pressure in the -- In order to check the pressure in the system use
system to be discharged. Filling up with coolant suitable instruments.
should only be carried out with the engine
stopped or idling (if hot).. WHEELS AND TIRES
-- Never fill up with fuel when the engine is running, -- Make sure that the tires are correctly inflated at
especially if hot, in order to prevent the outbreak the pressure specified by the manufacturer.
of fire as a result of fuel spillage. Periodically check the rims and tires for damage.
-- Never check or adjust fan belt tension when the -- Stand away from (at the side of) the tire when
engine is running. checking inflation pressure.
Never adjust the fuel injection pump when the
-- Only check pressure when the tractor is un-
tractor is moving.
loaded and the tires are cold, to avoid incorrect
-- Never lubricate the tractor when the engine is readings as a result of over--pressure. Do not use
running. parts of recovered wheels as incorrect welding
brazing or heating may weaken and eventually
ELECTRICAL SYSTEMS cause damage to the wheel.
-- If it is necessary to use auxiliary batteries, re- -- Never cut or weld a rim mounted with an inflated
member that both ends of the cables must be tire.
connected as follows: (+) with (+) and (--) with (--). -- To remove the wheels, lock both the front and
Avoid short--circuiting the terminals. GAS RE- rear tractor wheels. After having raised the trac-
LEASED FROM BATTERIES IS HIGHLY IN- tor, position supports underneath, according to
FLAMMABLE. During charging, leave the bat- regulations in force.
tery compartment uncovered to improve -- Deflate the tire before removing any objects that
ventilation. Never check the battery charge using may be jammed in the tire tread.
”jumpers” (metal objects placed on the ter- -- Never inflate tires using inflammable gases, as
minals). Avoid sparks or flames near the battery this may result in explosions and injury to by-
zone. Do not smoke to prevent explosion haz- standers.
ards.
-- Before servicing operations, check for fuel or
REMOVAL AND RE--FITTING
current leaks. Eliminate any eventual leaks be-
fore proceeding with work. -- Lift and handle all heavy parts using suitable ho-
isting equipment. Make sure that parts are sus-
-- Never charge batteries in confined spaces. Make
tained by appropriate hooks and slings. Use the
sure that there is adequate ventilation in order to
hoisting eyebolts for lifting operations. Extra care
prevent accidental explosion hazards as a result
should be taken if persons are present near the
of the accumulation of gases released during
load to be lifted.
charging operations.
-- Handle all parts carefully. Do not put your hands
-- Always disconnect the batteries before perform-
or fingers between parts. Wear suitable safety
ing any kind of servicing on the electrical system.
clothing -- safety goggles, gloves and shoes.
-- Avoid twisting chains or metal cables. Always
wear safety gloves when handling cables or
chains.
CONSUMABLES
NEW HOLLAND
QUANTITY NEW HOLLAND INTERNATIONAL
PARTS TO BE FILLED RECOMMENDED
liter (gal.) SPECIFICATION SPECIFICATION
PRODUCT
Water and liquid Water and liquid SAE1941 ASTM

AMBRA Antifreeze D4985 (EG)
Cooling system: AGRIFLU Fleetguard
without cab . . . . . . . . . . . . . . 10.0 (2.64) 50% + 50% ES Coolant EG
(Ethylene Glycol)
50% + 50%
Decanted and
Fuel tank: . . . . 65 (17.17) -- --
filtered fuel oil
Crankcase sump: AMBRA NH Break-In API

without filter: . . . . . . . . . . . . . 6.7 (1.77) Break-In Engine Oil (10W40) SE/CC
Engine Oil 10W40
(10W40)
with filter: . . . . . . . . . . . . . . . . 7.5 (1.98) NH Super Premium API
(15W40) CH-4/SS
AMBRA Engine Oil CCMC 04
SUPER GOLD UNI 20153
HSP MIL-L2104C
Engine Oil ACEA E3/E5
(15W40)
Brake control circuit . . . . . . 0.7 (0.18) AMBRA NH Brake Oil

BRAKE LHM (86541699DS) ISO 7308
0.5 (0.13) Mineral Brake Oil
Front axle:
axle case . . . . . . . . . . . . . . . . 4.5 (1.19)
TN55 lateral final drives wi-
thout brakes (each) . . . . . . . 0.8 (0.21)
TN55 lateral final drives with
brakes (each) . . . . . . . . . . . . 1.3 (0.34)
TN65, TN70 and TN75 late-
ral final drives without bra-
AMBRA MULTI NH 134D API GL4
kes (each) . . . . . . . . . . . . . . . 1.0 (0.26)
G134 Hydraulic Oil ISO 32/46
TN65, TN70 and TN75 late-
Hydraulic Oil SAE 10W--30
ral final drives with brakes
(each) . . . . . . . . . . . . . . . . . . 1.5 (0.40)
Rear transmission (bevel

gear pair, lateral final drives
and brakes), gearbox, hy-
draulic lift, power take--off
and hydrostatic steering: . . 42 (11.10)
AMBRA GR9 NH Super Premium

Compression cups . . . . . . . -- Multipurpose MP Lithium Grease NLGI 2
Grease (86506331)
SECTION 10 -- ENGINE -- CHAPTER 1 1
SECTION 10 -- ENGINE
Chapter 1 -- Engine
CONTENTS
Section Description Page

10 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Lubrication and cooling system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 001 10 Engine, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 001 30 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10 001 54 Engine, Removal--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10 414 10 Coolant Pump and Alternator Drive Belt -- Tension adjustment . . . . . . . . . . . . . . . . . . . . . . 72
10 101 53 Valve guides, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10 101 60 Injector holder casing, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 102 70 Front engine oil seal, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10 106 12 Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10 126 10 Fuel tank, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10 218 30 Engine injectors, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10 246 14 Bosch injection pump, Removal--Installation, timing and air bleed check . . . . . . . . . . . . . 86
10 254 44 Exhaust pipe, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 402 11 Coolant pump, Removal--Installation, with radiator removed . . . . . . . . . . . . . . . . . . . . . . . . 93
10 402 28 Coolant pump, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10 402 30 Thermostat, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 406 10 Radiator, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2 SECTION 10 -- ENGINE -- CHAPTER 1
GENERAL SPECIFICATIONS
Engine type:
-- Hp TN 55 -- type 8035.05B.529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 6--7
-- Hp TN 65 -- type 8035.05R.539 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 8--9
-- Hp TN 70 -- type 8035.25R.520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 97
-- Hp TN 75 -- type 8035.25.529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 10--11
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4--stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct
No. of in--line cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry force--fitted in cylinder
block
Piston diameter:
-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 mm (4.53 inches)
Total displacement:
-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
Compression ratio, models TN 55 and TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17:1 normal intake
Compression ratio, model TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5:1 turbocharged
Maximum power:
-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 kW (50 HP)
-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 kW (60 HP)
-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 kW (70 HP)
-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 kW (72 HP)
Max. power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 rpm
Max. torque speed: model TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . structural, cast iron
(continued)
(continued)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with gear pump
1st 50 hr oil (Break-in Engine Oil) . . . . . . . . . . . . . . . . . . . . . . . . . 10W-40 -- API SE/CC 10W-40
After 50 hr oil (AMBRA SUPER GOLD HSP Engine Oil) . . . . . 15W-40 -- API CH-4/SD
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 2:1
Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh screen on oil pick--up and filter
cartridge in delivery line
Normal oil pressure.
Ideal pressure readings obtained at Oil Pan Temperature of
100 °C ± 5 °C (212 °F ± 9 °F)
TN 55 and TN 65 at min ERPM (650 ± 25) . . . . . . . . . . . . . . . . . * > .69 bar (> 9.94 psi)
TN 55 and TN 65 at max ERPM (2475 ± 25) . . . . . . . . . . . . . . . * > 2.94 to 3.92 bar (> 42.6 to 56.8 psi)
TN 70 and TN 75 at min ERPM (650 ± 25) . . . . . . . . . . . . . . . . . * > 1.08 bar (> 15.62 psi)
TN 70 and TN 75 at max ERPM (2500 ± 25) * > 1.96 bar (> 28.4 psi)
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . built into pump housing
Valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 bar (50.8 psi)
For further lubrication technical data . . . . . . . . . . . . . . . . . . . . . . See page 19
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . water circulation
Radiator on models TN 55, TN 65 . . . . . . . . . . . . . . . . . . . . . . . . 3--row vertical pipes with copper fins
Radiator on model TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . . 4--row vertical pipes with copper fins
Fan, attached to coolant pump pulley . . . . . . . . . . . . . . . . . . . . . 6--blade steel exhauster fan
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane--type
Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . 1:1.25
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thermostat
Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coloured scale divided into 3 sections
Temperature ranges corresponding to each section:
-- initial white section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30o to 65o C (86o to 149o F)
-- middle green section (normal working conditions) . . . . . . . . 65o to 105o C (149o to 221o F)
-- final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105o to 115o C (221o to 239o F)
For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . See page 19
Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incorporated in control panel
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from gear on camshaft
Hour counter calibrated for engine speed of . . . . . . . . . . . . . . . 1800 rpm
(continued overleaf)
* > means greater than
(continued)
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated camshaft

located in engine block through tappets,
pushrods and rockers; camshaft is driven
by the crankshaft through helical gears
Inlet:
-- start: before TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12o
-- end: after BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31o
Exhaust:
-- start: before BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50o
-- end: after TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16o
Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.02 inches)
Valve clearance for normal running (engine cold):
-- inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 mm (0.01 ± 0.002 inches)
-- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 mm (0.01 ± 0.002 inches)
For further timing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 16

Fuel system
Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre--filter
and automatic dust ejector
Fuel supply pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . double diaphragm
Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and
replaceable cartridge on delivery line to
injection pump
Minimum fuel flow rate with pump shaft rotating at 1600 rpm . 100 litres/hour (26.42 gallons/hour)
Operated by eccentric cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on camshaft
BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type
All--speed governor, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights
Automatic advance regulator, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic
For further fuel system data:
For fixed advance (pump setting for start of delivery before
TDC) -- Pressure setting -- Injection order, and other
information regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . refer to the data for the relevant engine
type in the table on page 2
FUEL SYSTEM DATA
Turbocharger (model TN 70 and TN 75):
-- GARRETT type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 25
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type with incorporated speed

governor and automatic advance regulator
BOSCH pump:
-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 767
-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 766
-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 764--2
-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 764
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . counter--clockwise
Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2--3
Injectors:
BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500307714
-- Nozzle holder type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4791124
-- Nozzle type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 132S 1320 -- 99469341
Number of nozzle orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diameter of nozzle orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 mm (0.01 inches)
Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 to 272 bar (3771.2 to 3945.2 psi)
Fuel delivery lines -- BOSCH pump
-- type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99441952
-- dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 x 1.75 x 540 mm (0.24 x 0.07 x 21.26 in.)

MODEL TN 55 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 3/11 F 1150 L 767 -- VE 3/11 F 1150 L 767--1
ASSEMBLY DATA CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start ± 9o
be- 0.5o Test bench conforming to ISO 4008/1 .../2
fore TDC of cylinder 1 compression stroke. Injectors conforming to ISO 7440--A61 --
Plunger pre--lift for timing on engine: mm 1 from P.M.I. (1.688.901.027 and pad with calibrated hole ∅ 0.5
(with tools 291754 -- 291755). mm; 0.02 in.).
Cylinder No.1 delivery line union on pump: marked Injector pressure setting 250 to 253 bar (3626.1 to
with letter A. 5120.1 psi).
Supply pressure:
ASSEMBLY DIMENSIONS . . . . . . . . . 0.35 ± 0.05 bar (5.1 ± 0.7 psi).
Delivery pipes (conforming to ISO 4093.2):
SYMBOL K MS ya yb . . . . . . . . . 6 x 2 x 450 mm (0.24 x 0.08 x 17.72 in.)
Graduate drain time: . . . . . . . . . : 30”.
mm -- -- 38.5 to 40.5 42.8 to 48.0 Test liquid: ISO 4113 at a temperature of 45o ± 1oC
(in.) (1.52 to 1.59) (1.69 to 1.89)
(113o ± 33.8o F).
1. START OF DELIVERY
Plunger pre--lift from TDC: Pump rotation (viewed from drive side): Injection order: 1--2--3
mm -- counter--clockwise
2. ADVANCE REGULATOR STROKE

Rpm: 1200 Advance stroke: mm 0.7 to 1.1 (inches 0.03 to 0.04)
3. FUEL SUPPLY PUMP PRESSURE

Rpm: 1200 Internal pressure: bar 8.1 to 8.7 (psi 117.5 to 126.2)
4. FULL LOAD DELIVERY

Rpm: 700 Delivery per 1000 shots: cm3 59.5 to 60.5 Spread: cm3 -- 3.5
(gal.0.0157 to 0.0159) (gal. --0.000925)
5. SPREAD GOVERNOR AT IDLE SPEED

Rpm: 325 Delivery per 1000 shots: cm3 8.4 to 12.4 Spread: cm3 (gal.)
(gal. 0.0022 to 0.0032)
6. SPREAD GOVERNOR AT MAXIMUM SPEED

Rpm: 1220 Delivery per 1000 shots: cm3 27 to 33 Spread: --
(gal. 0.007 to 0.008)
7. DELIVERY AT STARTING
Rpm: 100 Delivery per 1000 shots: cm3 60 to 100 (gal. 0.016 to 0.026)
8. INJECTION ADVANCE PROGRESSION

Rpm 1200 1250
Advance stroke mm (in.) 0.7 to 1.1 (0.03 to 0.04) 1.4 to 1.8 (0.06 to 0.07)
9. TRANSFER PRESSURE PROGRESSION

Rpm 1200 400 700
Internal pressure supply bar (psi) 8.1to 8.7 (117.5 to 126.2) 3.2 to 3.8 (46.4 to 55.1) 4.7 to 6.1 (68.1 to 88.5)
10. BACKFLOW
Rpm 400 1150
Backflow l/h (gal./h) 13 to 33 (3.43 to 8.72) 25 to 37 (6.60 to 9.77)
Note: the values shown above in brackets must be used for checking purposes only.
(continued)
11. DELIVERY PROGRESSION

Rpm Delivery per 1000 shots: cm3 (gallons)
1280 0 to 3.0 (0 to 0.0008)
1220 27 to 33 (0.007 to 0.008)
1150 50.5 to 53.5 (0.013 to 0.014)
700 59.5 to 60.5 (0.0157 to 0.0159)
400 52.8 to 60.8 (0.0139 to 0.016)
12. ZERO CAPACITY (STOP)

Rpm Voltage (volts) Delivery per 1000 shots: cm3 (gal.)
325 0 0 to 3 (0 to 0.0008)
13. DELIVERY CHECK AT IDLE SPEED

Rpm 325 400 250
Delivery per 1000 shots: cm3 (gal.) 8.4 to 12.4 0 to 3.0 31.2 to 39.2
(0.002 to 0.003) (0 to 0.0008) (0.008 to 0.010)
14. AUTOMATIC START SUPPLEMENT

100 60 to 100 (0.0158 to 0.0264)
250 49 to 57 (0.0129 to 0.0151)
150 75 to 105 (0.0198 to 0.0277)
BENCH TEST PERFORMANCE DATA

Test conditions
Fixed advance before TDC cylinder No.1 in compression stroke: Relative humidity 70o/o ± 5.
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature
25o ± 3o C (77o ± 37.4o F).
Atmospheric pressure 990 ± 10 mbar (14.36 ± 0.15 psi). Specific gravity of diesel fuel
840 g/l. (7 lb./gal.)
Throttle Engine speed Power output with engine run--in for a total of: Fuel consumption
lever Braking load applied 2 hours 50 hours
position rpm kW (hp) kW (hp) kg/h (lb./h)
For maximum 35.7 to 37.9 8.0 to 8.5
Maximum 2300 ≥ 34.9 (47.4)
power output (48.5 to 51.5) (17.64 to 18.74)
Maximum 1400 ≥ 27.3 (37.1)
torque (37.9 to 40.3) (13.23 to 14.11)
Maximum None (no--load) 2470 to 2500 -- -- --
Minimum None (no--load) 625 to 675 -- -- --
TYPE VE 3/11 F 1150 L 766 -- VE 3/11 F 1150 L 766--1

Pump timing on engine: delivery start 9o ± 0.5o be- Test bench conforming to ISO 4008/1 .../2
Plunger pre--lift for timing on engine: mm 1 (0.04 in.) (1.688.901.027 and pad with calibrated hole ∅ 0.5
from P.M.I. (with tools 291754 -- 291755). mm; 0.02 in.).
Supply pressure:
. . . . . . . . . 0.35 ± 0.05 bar (5.1 ± 0.7 psi).
ASSEMBLY DIMENSIONS
Delivery pipes (conforming to ISO 4093.2):
SYMBOL K MS ya yb
. . . . . . . . . 6 x 2 x 450 mm (0.24 x 0.08 x 17.72 in.)
Graduate drain time: . . . . . . . . . : 30”.
mm -- -- 36.5 to 38.5 41.4 to 46.6 Test liquid: ISO 4113 at a temperature of 45o ± 1oC
(in.) (1.44 to 1.52) (1.63 to 1.83)
(113o ± 33.8o F).
Plunger pre--lift from TDC: Pump rotation (viewed from drive side): Injection order:1--2--3
mm -- counter--clockwise

Rpm: 1240 Advance stroke: mm 0.4 to 1.4 (inches 0.016 to 0.055)

Rpm: 1200 Internal pressure: bar 7.7 to 8.9 (psi 111.7 to 129.1)
4. FULL LOAD DELIVERY

Rpm: 700 Delivery per 1000 shots: cm3 64.1 to 69.1 Spread: cm3 ≤ 3.5 (gal. ≤ 0.000925)
(gal. 0.017 to 0.018)

Rpm: 325 Delivery per 1000 shots: cm3 15.9 to 23.9 Spread: cm3 ≤ 4.0 (gal. ≤ 0.00106)
(gal. 0.004 to 0.006)

Rpm: 1200 Delivery per 1000 shots: cm3 43.5 to 54.5 Spread:--
(gal. 0.011 to 0.014)

Rpm 1240 1280

Rpm 1200 400
Internal pressure supply bar (psi) 7.7 to 8.9 (111.7 to 129.1) 3.5 to 4.7 (50.8 to 68.17)
10. BACKFLOW
Rpm 400 1100
Backflow l/h (gal./h) 14 to 22 (3.70 to 5.81) 22 to 42 (5.81 to 11.10)
(continued)

1270 0 to 3.0 (0 to 0.0008)
1200 43.5 to 54.5 (0.0114 to 0.0144)
700 64.1 to 69.1 (0.0169 to 0.01825)
1100 63.5 to 69.5 (0.0167 to 0.01836)
400 55.8 to 63.8 (0.0147 to 0.01685)
1150 61.5 to 69.5 (0.1625 to 0.01836)

325 0 0 to 3.0 (0 to 0.0008)

Rpm 325 360 275
Delivery per 1000 shots: cm3 (gal.) 15.9 to 23.9 0 to 3.0 37.6 to 51.6
(0.004 to 0.006) (0 to 0.0008) (0.010 to 0.014)
14. AUTOMATIC START SUPPLEMENT

100 55 to 95 (0.0145 to 0.0251)
270 52.5 to 62.5 (0.0139 to 0.0165)
180 73 to 103 (0.0193 to 0.0272)

Test conditions
(see previous page)
25o ± 3o C (77o ± 37.4o F).
840 g/l. (7 lb./gal.)
position rpm kW (hp) kW (hp) kg/h (lb./h)
For maximum 43 to 45.6 9.9 to 10.5
Maximum 2300 ≥ 42 (57.1)
power output (58.5 to 62) (21.83 to 23.15)
Maximum 1400 ≥ 29.4 (40)
torque (40.8 to 43.2) (14.11 to 14.99)
MODELS TN 70 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE -- VE 4/11 F 1150 L 764--2
Pump timing on engine: delivery start 6o ± 0.5o before Test bench conforming to ISO 4008/1 .../2
TDC of cylinder 1 compression stroke. Injectors conforming to ISO 7440--A61 --
Plunger pre--lift for timing on engine: mm 1 from P.M.I. (1.688.901.027 and pad with calibrated hole
(with tools 291754 -- 291755). ∅ 0.5 mm; 0.02 in.).
Supply pressure: 0.35 to± 0.05 bar (5.1 ± 0.7 psi).
ASSEMBLY DIMENSIONS Delivery pipes (conforming to ISO 4093.2):
SYMBOL K VHA ya yb mm 6 x 2 x 450 (0.24 x 0.08 x 17.72 in.)
Graduate drain time: . . . . . 30”.
mm -- 30,1 38.6 to 40.6 40.4 to 45.6 Test liquid: ISO 4113 at a temperature of 45o ±to 1oC
(1.45 to 1.60) (1.59 to 1.79) (113o ± 33.8o F).
Plunger pre--lift from TDC: mm -- Pump rotation (viewed from drive side): Injection order:1--2--3--4--2
counter--clockwise
Rpm: 900 Advance stroke: mm 1.2 to 1.4
(inches 0.047 to 0.055)
Rpm: 900 Internal pressure: bar 6.8 to 7.4
(psi 98.6 to 107.3)
4. FULL--LOAD DELIVERY WITH BOOSTER PRESSURE
Rpm: 700 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 80.5 to 81.5 Spread: cm3 ≤ 3.5
(gal. 0.0213 to 0.0215) (gal. ≤ 0.000925)
5. FULL--LOAD DELIVERY WITHOUT BOOSTER PRESSURE
Rpm: 600 Portata per 1000 mandate: cm3 73,5 ÷ 74,5
Rpm: 325 Delivery per 1000 shots: cm3 10.5 to 12.5 Spread: cm3 ≤ 4.5
(gal. 0.0027 to 0.0033) (gal. ≤ 0.0012)
Rpm: 1200 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 53 to 54
(gal. 0.0140 to 0.0142)
Rpm: 100 Delivery per 1000 shots: cm3 80 to 110
(gal. 0.0211 to 0.0290)
LDA pressure kPa 100
Rpm 400 900
Internal supply pressure bar (psi) 3.4 to 4.4 (49.3 to 63.8) 6.8 to 7.4 (98.6 to 107.3)
Rpm 900 1000
11. BACKFLOW
Rpm 600 1150
LDA pressure kPa 0 100
Backflow cm3 (gal.) 19 to 29 (0.005 to 0.007) 24 to 38 (0.006 to 0.010)
Note: The values shown above in brackets must be used for checking purposes only.
(segue)

Rpm LDA pressure kPa Delivery per 1000 shots: cm3 (gal.)
600 35 78,9 to 79,9 (0.0208 to 0.0211)
1270 100 0 to 3.0 (0 to 0.0008)
1200 100 53 to 54 (0.0140 to 0.0142)
1150 100 67,5 to 71,5 (0.0178 to 0.0188)
700 100 80,5 to 81,5 (0.0212 to 0.0215)
600 0 73,5 to 74,5 (0.0194 to 0.0197)

Rpm 325 410
Delivery per 1000 shots: cm3 (gal.) 10.5 to 12.5 (0.0027 to 0.0033) 0 to 3.0 (0 to 0.0008)
Note: The values shown above in brackets must be used for checking purposes only.

325 0 0 to 3.0 (0 to 0.0008)
15. AUTOMATIC START CAPACITY SUPPLEMENT

100 -- 80 to 110 (0.0211 to 0.0290)
250 -- 74 to 86 (0.0195 to 0.0227)

Test conditions
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature 25o C (77o F).
840 g/l. (7 lb./gal.) at a temperature of
15 oC (59o F).
position rpm kW (hp) kW (hp) kg/h (lbs./h)
For maximum 46,5 to 49,5 10,2 to 10,8

Maximum 2300 ≥ 45,6 (62)
power output (63 to 67) (22.5 to 23.8)
For maximum 36,5 to 39,4 7,95 to 8,45
Maximum 1400 ≥ 35,8 (48,7)
torque (49,6 to 53,6) (17.5 to 18.6)
TYPE VE 3/11 F 1150 L 764 -- VE 3/11 F 1150 L 764--1
Pump timing on engine: delivery start 6o ± 0.5o be- Test bench conforming to ISO 4008/1 .../2
Plunger pre--lift for timing on engine: mm 1 (0.04 in.) (1.688.901.027 and pad with calibrated hole ∅ 0.5
from P.M.I. (with tools 291754 -- 291755). mm; 0.02 in.).
ASSEMBLY DIMENSIONS Supply pressure:
. . . . . . . . . 0.35 ± 0.05 bar (5.1 ± 0.7 psi).
SYMBOL K MS ya yb Delivery pipes (conforming to ISO 4093.2):
mm -- -- 38.6 to 40.6 42.9 to 48.1
. . . . . . . . . 6 x 2 x 450 mm (0.24 x 0.08 x 17.72 in.)
(in.) (1.45 to 1.60) (1.69 to 1.89) Graduate drain time: . . . . . . . . . : 30”.
Test liquid: ISO 4113 at a temperature of 45o ± 1oC
(113o ± 33.8o F).
Plunger pre--lift from TDC: mm -- Pump rotation (viewed from drive side): counter--clockwise Injection order:1--2--3
Rpm: 1240 LDA pressure: kPa 100 Advance stroke: mm 1.3 to 1.9
(inches 0.051 to 0.075)
Rpm: 1220 LDA pressure: kPa 100 Internal pressure: bar 8.3 to 9.5
(psi 120.4 to 137.8)
4. FULL--LOAD DELIVERY WITH BOOSTER PRESSURE
Rpm: 700 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 88 to 93 Spread: cm3 ≤ 3.5
(gal. 0.023 to 0.025) (gal. ≤ 0.000925)
5. FULL--LOAD DELIVERY WITHOUT BOOSTER PRESSURE
Rpm: 500 LDA pressure: kPa 0 Delivery per 1000 shots: cm3 78.2 to 83.2 Spread: cm3 -- (gal. --)
(gal. 0.021 to 0.022)
Rpm: 325 LDA pressure: kPa 0 Delivery per 1000 shots: cm3 3.5 to 14.5 Spread: cm3 ≤ 4.5
(gal. 0.0009 to 0.0038) (gal. ≤ 0.001189)
Rpm: 1200 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 47.5 to 63.5 Spread: cm3 -- (gal. --)
(gal. 0.0125 to 0.01677)
Rpm 1180 1240
Rpm 500 1220 1180
Internal supply pressure bar (psi) 3.8 to 5.0 (55.1 to 72.5) 8.3 to 9.5 (120.4 to 137.8) 7.9 to 9.1 (114.6 to 132)
11. BACKFLOW
Rpm 500 1150
LDA pressure kPa 0 100
Backflow for 10 s l/h (gal./h) 15 to 31 (3.96 to 8.19) 15 to 45 (8.19 to 12.68)
(continued)
1300 100 0 to 3.0 (0 to 0.0008)
1200 100 47.5 to 63.5 (0.01254to 0.0168)
700 100 88 to 93 (0.0232 to 0.0246)
600 42.5 82.8 to 90.8 (0.0219 to 0.0240)
500 0 78.2 to 83.2 (0.0207 to 0.0220)
1150 100 74.6 to 80.6 (0.0197 to 0.0213)
500 100 89.5 to 96.5 (0.0236 to 0.0255)

Rpm: 325 Voltage (volts): 0 Delivery per 1000 shots: cm3 0 to 3.0
(gal. 0 to 0.0008)

Rpm 325 410
Delivery per 1000 shots: cm3 (gal.) 3.5 to 14.5 0 to 3.0
(0.0009 to 0.0038) (0 to 0.0008)
15. AUTOMATIC START CAPACITY SUPPLEMENT
Rpm Delivery per 1000 shots: cm3 (gal.)
100 85 to 125 (0.0225 to 0.0330)
250 71 to 91 (0.0188 to 0.0240)
160 100 to 130 (0.0264 to 0.0343)

Test conditions
(see previous page)
25o ± 3o C (77o ± 37.4o F).
840 g/l. (7 lb./gal.)
Engine Fuel
Throttle Power output with engine run--in for a total of:
speed consumption
l
lever Braking load applied
2 hours 50 hours
position
rpm kW (hp) kW (hp) kg/h (lb./h)
51.4 to 54.5 (1) 11.9 to 12.6

For maximum
Maximum 2300 ≥ 50.4 (68.5) (26.24 to
power output (69.9 to 74.1) 27.78)
41.6 to 44.2 (2) 9.1 to 9.6
For maximum
Maximum 1400 ≥ 40.8 (55.4) (20.06 to
torque (56.6 to 60.1) 21.16)
2475 to
Maximum None (no--load) -- -- --
2525
Note: Air delivery pressure (1) bar 0.95 to 1.1 (psi 13.8 to 16) -- (2) bar 0.55 to 0.65 (psi 8 to 9.4).
FUEL SUPPLY PUMP DATA mm (inches)
Eccentricity of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 (0.1181)
Diameter of drive shaft at bushings . . . . . . . . . . . . . . . . . . . . . . . . . 31.975 to 32.000 (1.2588 to 1.2598)
Internal diameter of installed and reamed bushings . . . . . . . . . . . 32.050 to 32.075 (1.2618 to 1.2628)
Interference between bushings and seats . . . . . . . . . . . . . . . . . . . . 0.063 to 0.140 (0.0025 to 0.0055)
Assembly clearance between shaft and bushings . . . . . . . . . . . . . 0.050 to 0.100 (0.0020 to 0.0039)
Thickness of internal washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45 to 1.50 (0.0571 to 0.0496)
Thickness of external washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.93 to 3.00 (0.1154 to 0.1181)
CRANKCASE/CYLINDER BLOCK DATA mm (inches)
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast--iron monobloc with replaceable

dry--fitted cylinder liners, incorporating
seatings for crankshaft bearings,
camshaft and pushrod/tappet
assemblies
Internal diameter of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . 104.000 to 104.024 (4.0945 to 4.0954) (1)
External diameter of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . 107.020 to 107.050 (4.2134 to 4.2146)
Diameter of cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.850 to 106.900 (4.2067 to 4.2087)
Interference fit between cylinder liners and bores . . . . . . . . . . . . . 0.120 to 0.200 (0.0047 to 0.0079)
Liner internal diameter oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 to 0.8 (0.0157 to 0.0315)
Liner external diameter oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.0079)
Maximum permissible liner ovality or taper due to wear (2) . . . . . 0.12 (0.0047)
Diameter of main shell bearing seats . . . . . . . . . . . . . . . . . . . . . . . 84.200 to 84.230 (3.3150 to 3.3161)
Diameter of camshaft bearing seats:
-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.780 to 54.805 (2.1567 to 2.1577)
-- centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.280 to 54.305 (2.1370 to 2.1380)
-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.780 to 53.805 (2.1173 to 2.1183)
Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . 15.000 to 15.018 (0.5906 to 0.5913)
Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 -- 0.2 -- 0.3

(0.0039 -- 0.0079 -- 0.0118)
(1) Measured after press--fitting and reaming.
(2) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.
CRANKSHAFT AND BEARINGS DATA mm (inches)
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . balanced with integral counterweights
Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.791 to 79.810 (3.1414 to 3.1421) (1)
Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)
Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . 2.168 to 2.178 (0.0854 to 0.0857)
Main bearing shell undersizes (internal diameter) . . . . . . . . . . . . . 0.254 -- 0.508 -- 0.762 -- 1.016
(0.01 -- 0.02 -- 0.03 -- 0.04)
Bearing shell to journal clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.034 to 0.103 (0.0013 to 0.0041)
Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . 0.180 (0.0071)
Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.725 to 63.744 (2.5089 to 2.5096) (1)
Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)
Standard big--end bearing shell thickness . . . . . . . . . . . . . . . . . . . 1.805 to 1.815 (0.0711 to 0.0715)
Big--end bearing shell undersizes (internal diameter) . . . . . . . . . . 0.254 -- 0.508 -- 0.762 -- 1.016
(0.01 -- 0.02 -- 0.03 -- 0.04)
Big--end bearing shell to crankpin clearance . . . . . . . . . . . . . . . . . . 0.033 to 0.087 (0.0013 to 0.0034)
Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.180 (0.0071)
Standard crankshaft thrust washer thickness . . . . . . . . . . . . . . . . . 3.378 to 3.429 (0.1330 to 0.1350)
Thrust washer oversizes (thickness) . . . . . . . . . . . . . . . . . . . . . . . . 0.127 -- 0.254 -- 0.381 -- 0.508

(0.005 -- 0.01 -- 0.015 -- 0.02)
Width of main bearing including thrust washers . . . . . . . . . . . . . . . 31.766 to 31.918 (1.2506 to 1.2566)
Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . 32.000 to 32.100 (1.2598 to 1.2638)
Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.082 to 0.334 (0.0032 to 0.0131)
Maximum permitted wear endfloat ......................... 0.40 (0.0157)

Maximum ovality or taper of journals and crankpin after
regrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 (0.0004)
Maximum ovality or taper of journals and crankpin . . . . . . . . . . . . 0.05 (0.0020)
Maximum tolerance for alignment of crankshaft journals with

crankshaft supported on the two outer journals . . . . . . . . . . . . . . . 0.10 (0.0039)
Maximum tolerance for alignment, in both directions, of each pair

of crankpins relative to crankshaft journals . . . . . . . . . . . . . . . . . . 0.25 (0.0098)
Maximum tolerance for run--out between the outer surfaces of

the crankshaft journals and the crankshaft centreline . . . . . . . . . ± 0.10 (0.0039)
(1)Crankshafts with 0.1 mm undersize journals, crankpins and, consequently, undersize bearing shells may be fitted in
factory production.
(continued)
CRANKSHAFT AND BEARINGS DATA mm (inches)
Maximum permitted tolerance on run--out of flywheel mounting

flange surface relative to the crankshaft centreline, measured with
1/100 mm scale dial gauge resting on front flange surface (A, page
63 ) at a diameter of 108 mm (4.25 in.) (total gauge reading) . . . . . 0.025 (0.0010)
Maximum permitted tolerance on co--axial alignment of flywheel

centering (B, page 63 ) relative to the crankshaft journals (total
gauge reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 (0.0002)
CONNECTING ROD DATA mm (inches)
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast--iron with oil way
Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . . 41.846 to 41.884 (1.6475 to 1.6490)
Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . . 41.979 to 42.017 (1.6527 to 1.6542)
Interference between small end bushing and seat . . . . . . . . . . . . 0.095 to 0.171 (0.0037 to 0.0067)
Inside diameter of small end bushing (measured after fitting) . . . 38.004 to 38.014 (1.4962 to 1.4966)
Diameter of big end bearing seats . . . . . . . . . . . . . . . . . . . . . . . . . . 67.407 to 67.422 (2.6538 to 2.6544)
Max. tolerance for parallelism between the small end and the big
end axes measured at 125 mm (4.92 in.) . . . . . . . . . . . . . . . . . . . . ± 0.07 (0.0028)
Maximum weight difference between con rods in same engine . . 25 grams (0.055 lb.)
PISTON DATA mm (inches)
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . light alloy with two compression rings

and one oil control ring
Standard piston diameter, measured at 57 mm (2.24 in.)from

skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . . 103.812 to 103.826
(4.0871 to 4.0876)
Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.174 to 0.212

(0.0068 to 0.0083)
Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 -- 0.8 (0.0157 -- 0.0315)
Piston protrusion at TDC from cylinder block face . . . . . . . . . . . . . 0.355 to 0.761 (0.0140 to 0.0300)
Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.983 to 37.990 (1.4954 to 1.4957)
Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . . 37.993 to 38.000 (1.4958 to 1.4961)
Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . 0.003 to 0.017 (0.0001 to 0.0007)
Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . . 0.014 to 0.031 (0.0006 to 0.0012)
Maximum weight difference between pistons in same engine . . . 20 grams (0.044 lb.)
Piston ring groove clearance (measured vertically):
-- top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 to 0.122 (0.0035 to 0.0048)

-- second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 to 0.092 (0.0024 to 0.0036)
-- bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 to 0.075 (0.0016 to 0.0030)

Max. permissible clearance (wear limit):
-- top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 (0.0197)
-- second and bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.0079)
Piston ring end gap (fitted):
-- top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.65

(0.0157 to 0.0256)
-- second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.55

(0.0118 to 0.0217)
-- bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.60

(0.0118 to 0.0236)
Maximum permissible gap (wear limit) . . . . . . . . . . . . . . . . . . . . . . . 1.20 (0.0472)

VALVE TIMING GEAR DATA mm (inches)
Timing gear tooth backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.160 (0.0063)
Inside diameter of intermediate gear bushings

(fitted and reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.050 to 37.075 (1.4587 to 1.4596)
Diameter of intermediate gear journal . . . . . . . . . . . . . . . . . . . . . . . 36.975 to 37.000 (1.4557 to 1.4567)
Journal to bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.100 (0.0020 to 0.0039)

Bushing interference fit in seat in intermediate gear . . . . . . . . . . . 0.063 to 0.140 (0.0025 to 0.0055)
Outside diameter of camshaft bearings:
-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.875 to 54.930 (2.1604 to 2.1626)

-- centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.375 to 54.430 (2.1407 to 2.1429)
-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.875 to 53.930 (2.1211 to 2.1232)

Interference between bearings and seats in cylinder block . . . . . 0.070 to 0.150 (0.0028 to 0.0059)
Inside diameter of camshaft bearings (fitted and reamed):

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.080 to 51.130 (2.0110 to 2.0130)
-- centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.580 to 50.630 (2.1604 to 2.1626)
-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.080 to 50.130 (2.1604 to 2.1626)
Diameter of camshaft journals:
-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.970 to 51.000 (1.9913 to 2.0079)
-- centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.470 to 50.500 (1.9870 to 1.9882)
-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.970 to 50.000 (1.9673 to 1.9685)
Clearance between camshaft journals and bearings . . . . . . . . . . . 0.080 to 0.160 (0.0031 to 0.0063)

Camshaft endfloat between thrust plate and seat on camshaft . . 0.070 to 0.220 (0.0028 to 0.0087)
For further timing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 4
TAPPET DATA mm (inches)
Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.000 to 15.018 (0.5906 to 0.5913)

Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . . 14.950 to 14.970 (0.5886 to 0.5894)
Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 to 0.068 (0.0012 to 0.0027)

Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 -- 0.2 -- 0.3
(0.0039 -- 0.0078 -- 0.0118)
ROCKER ARM -- VALVE DATA mm (inches)
Diameter of shaft bores in rocker arms . . . . . . . . . . . . . . . . . . . . . . 18.016 to 18.034 (0.7093 to 0.7100)
Diameter of rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.982 to 18.000 (0.7080 to 0.7087)

Rocker shaft to rocker arm bore clearance . . . . . . . . . . . . . . . . . . 0.016 to 0.052 (0.0006 to 0.0020)
Rocker arm spacing springs:
-- free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.5 (2.3425)
-- length under load of 46 to 52 N (4.7 to 5.3 kg) . . . . . . . . . . . . 44 (1.7323)
Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 (0.0177)
Valve clearance for normal running (engine cold):
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 (0.0118 ± 0.0020)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 (0.0118 ± 0.0020)
Cam lift:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.67 (0.2232)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.95 (0.2343)

CYLINDER HEAD DATA mm (inches)

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with valve seats cut directly in the
casting and press--fitted steel valve
guides.
Original height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 (3.6220)
Maximum face re--grinding depth . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 (0.0197)
Diameter of standard valve guide bores in head . . . . . . . . . . . . . . 13.950 to 13.983 (0.5492 to 0.5505)
Outside diameter of standard valve guides . . . . . . . . . . . . . . . . . . . 13.993 to 14.016 (0.5509 to 0.5518)
Guide interference fit in bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 to 0.066 (0.0004 to 0.0026)
Inside diameter of valve guide (fitted in head) . . . . . . . . . . . . . . . . 8.023 to 8.043 (0.3159 to 0.3167)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.985 to 8.000 (0.3144 to 0.3150)
Assembly clearance between valve stem and guide . . . . . . . . . . . 0.023 to 0.058 (0.0009 to 0.0023)
Maximum run--out of valve guided on its stem measured through
360o with dial gauge contact point resting on valve head contact
band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 (0.0012)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.0079)
Valve seat angle in head:

-- inlet valve . . . . ...................................... 60o ± 5’
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45o ± 5’
Valve face angle:

-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60o 30’ ± 7’
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45o 30’ ± 7’
Valve head diameter:

-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.300 to 45.500 (1.7835 to 1.7913)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.500 to 37.750 (1.4764 to 1.4862)
Valve stand--in relative to cylinder head face . . . . . . . . . . . . . . . . . 0.7 to 1.0 (0.0276 to 0.0394)
Maximum permissible valve stand--in . . . . . . . . . . . . . . . . . . . . . . . . 1.3 (0.0512)
Inlet and exhaust valve springs:

-- free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.6 (1.7559)
-- length with valve closed, under load of 256 to 284 N
(26.1 to 28.9 kg -- 57.5 to 63.7 lb.) . . . . . . . . . . . . . . . . . . . . . . . 34 (1.3386)
-- length with valve open, under load of 502 to 554 N
(51.2 to 56.5 kg -- 112.9 to 124.6 lb.) . . . . . . . . . . . . . . . . . . . . . 23.8 (0.9370)
Injector protrusion relative to head face:

• BOSCH injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 1.1 (0.0118 to 0.0433)
mm (inches)
LUBRICATION SYSTEM DATA
TN 55 and TN 65 TN 70 and TN 75
Assembly clearance between oil pump drive shaft and bushing . 0.016 to 0.055 --
(0.0006 to 0.0022)
Clearance between shaft and driven gear . . . . . . . . . . . . . . . . . . . . 0.033 to 0.066 --
(0.0013 to 0.0026)
Tooth backlash between drive and driven gears . . . . . . . . . . . . . . . 0.100 (0.0039) --
Radial clearance between drive and driven gears and housing . . 0.060 to 0.170 --
(0.0024 to 0.0067)
Thickness of drive and driven gears . . . . . . . . . . . . . . . . . . . . . . . . . 40.961 to 41.000 --
(1.6126 to 1.6142)
Height of gear seat in pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.025 to 41.087 --
(1.6152 to 1.6176)
Endfloat between gears and gear housing in pump . . . . . . . . . . . . 0.025 to 0.126 --
(0.0010 to 0.0050)
Pressure relief valve spring --
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 (1.7717) 35.9 (1.4134)
-- spring length under load of 45 to 49 N (4.6 to 5 kg) . . . . . . . . 37.5 (1.4764) --
-- spring length under load of 88 to 94 N (9 to 9.6 kg) . . . . . . . . 30.5 (1.2008) --
-- spring length (2, fig. 149) under load of 127.8 to 141.2 N
(130 to 144 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 29 (1.1417)
-- spring length (2, fig. 149) under load of 233.4 to 258 N
(238 to 263 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 23.2 (0.9134)
For further lubrication technical data . . . . . . . . . . . . . . . . . . . . . . . . See page 3 --
COOLING SYSTEM DATA mm (inches)

Interference fit between pump impeller and shaft . . . . . . . . . . . . . 0.017 to 0.059 (0.0007 to 0.0023)
Interference fit between fan hub and shaft . . . . . . . . . . . . . . . . . . . 0.024 to 0.058 (0.0009 to 0.00228)
Interference fit between front seal bushing and impeller . . . . . . . . 0.012 to 0.058 (0.0005 to 0.00228)
For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 3
TORQUE SETTINGS WITH ANGLE
Torque setting
PART Thread Angle
Nm ft-lbs
Cylinder head bolts (2, page 23) . . . . . . . . . . . . . . M 12 x 1.25 70 52 90o + 90o
Main bearing cap bolts (4) . . . . . . . . . . . . . . . . . . . M 14 x 1.5 80 59 90o
Big--end cap bolts (5) . . . . . . . . . . . . . . . . . . . . . . . M 11 x 1.5 40 30 60o
Flywheel mounting bolts (3) . . . . . . . . . . . . . . . . . . M 12 x 1.25 40 30 60o
TIGHTENING TORQUE DATA

Tightening torque
PART Thread
Nm ft-lbs
Rocker shaft pedestal bolts (1, page 23) . . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Crankshaft hub retaining nut (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 30 x 1.5 294 217
Fan and alternator pulley bolts (6) . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 55 41
Additional counterweight retaining bolts (1, page 24) . . . . . . . . . . . . M 12 x 1.25 110 81
Inlet manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Alternator and belt tension adjustment nut . . . . . . . . . . . . . . . . . . . M 10 x 1.25 55 41
Coolant pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10x1.25 55 41
Tappet cover nuts (1, fig, 48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 15 11
Rocker shaft pedestal bolts (2, fig. 49) . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Oil pump and pump cover retaining bolts (1, fig. 57) . . . . . . . . . . . M8 25 18
Timing gear case and cover bolts (1, fig. 61) . . . . . . . . . . . . . . . . . M8 25 18
Intermediate flanged journal bolts (1, fig. 64) . . . . . . . . . . . . . . . . . M 10 x 1.25 55 41
Camshaft thrust plate retaining bolts (2, fig. 65) . . . . . . . . . . . . . . . M8 35 26
Rear crankcase cover bolts (2, fig. 85) . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Tappet adjuster locknuts (1, fig. 104) . . . . . . . . . . . . . . . . . . . . . . . . M8 22 16
Nuts for injector mounting studs (1, fig. 105) . . . . . . . . . . . . . . . . . M8 25 (*) 18 (*)
Exhaust manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Injection pump mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Sump pan retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 69 51
-- timing gear seal, cover and casing . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 39 to 49 29 to 36
-- flywheel housing crankcase and casing:
models TN 55 and TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 49 to 59 36 to 44
models TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 49 to 69 36 to 51
(*) Tighten nuts in two stages: see operations described in fig. 105.
TOOLS X 293231 Bush for intake/exhaust valve guide
installation (with 291046).
Warning -- The operations described in this section
can only be carried out with ESSENTIAL tools indi- X 291177 Valve guide reamer.
cated by an (X).
X 291050 Valve spring compressor.
To work safely and efficiently and obtain the best re-
sults, it is also necessary to use the recommended X 293270 Set of grinding tools for regrinding in-
specific tools listed below and certain other tools jector seat.
which are to be made according to the drawings in-
cluded in this manual. X 291182 Extractor for coolant pump impeller.
X 293280 Drift for installation of coolant pump im-

List of specific tools required for the various peller seal.
operations described in this section.
293814 Charger impeller reaction block (for 90
hp TN 70 and TN 75).
290740 Engine lifting hook.
290090 Revolving engine service stand. 293786 Wrench for injection pump delivery line
unions.
293860 Set of engine mounting brackets for re-
volving stand 290090. 293671 Injector cleaning kit.
X 291309 Compression test kit. X 293761 Wrench set for injector dismantling
(with 295008).
292870 Engine oil pressure test kit.
290284 Hand pump for injector calibration test.
293240 Check set, turbo charger (for 90 hp
TN 70 and TN 75).
X 291160 Piston ring pliers. Injection pump bench test
X 291048 Piston ring clamp.

291754 Dial gauge (1/100 mm, 5 mm stroke, ∅
X 292248 Protractor for angular torque measure- 40 mm with 291755).
ment.
291755 Device for BOSCH injection pump tim-
X 291504 Puller for crankshaft pulley hub. ing on engine (with 291754).
X 291883 Wrench for valve clearance adjust- X 295042 Extractor for injection pump drive gear.
ment.
X Test Cylinder Compression
X 291046 Drift for valve guide extraction / instal-
(dummy injector)
lation.
Order a complete injector assembly
X 294027 Twist bit for enlarging valve guide bore. (500307714) from parts. Remove the
internal guts. Use the hollowed injector
X 294028 8o tapered grinder for swaging exhaust to screw into engine and the other end
valve guides. for the gage.
Splining tool to be manufactured for assembling
the crankshaft front seal (print on the tool no. 34.5 (1.36)
50138 -- Values in mm -- inches). 10.2
Construct in UNI C40 material. (0.40)
1.5 x 15
(0.06 x 0.60)
Ø 59.2 -- 59.8
(2.33 -- 2.35)
Ø 83 (3.27)
Ø 46 (1.81)
24.1 -- 24.5
(0.95 -- 0.96)
26102
Splining tool to be manufactured for assembling

4.5 -- 5.5
the crankshaft rear seal (print on the tool no. 30 (1.18) (0.18 -- 0.22)
50139 -- Values in mm -- inches).
Construct in UNI C40 material.
Ø 129 (5.08)
Ø 115 (4.53)
Ø 135.5 -- 136
(5.33 --5.35 )
Ø 145 (5.71)
26103
2
5 4 3
25355
3
Longitudinal section of engine (modelsTN 55 and TN 65).
25356
4
Cross--section of engine (modelsTN 55 and TN 65).
SECTION 10 -- ENGINE -- CHAPTER 1
Engine lubrication system 5

1. Oil filler cap -- 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the pressure at the outlet by 1.5--1.7 bar/cm2) --
3. Filter -- 4. Switch for low engine oil pressure warning (on dashboard) --
5. Dipstick -- 6. Pump -- 7. Oil pressure limiting valve -- 8. Screen filter on pick--up pipe
27
a b
1 2
3
4
25363
6 5
Engine cooling system.

A. Coolant circulation with thermostat valve closed 3. Electric thermometer for engine coolant temperature
B. Coolant circulation with thermostat valve open 4. Temperature value transmitter
1. Thermostat 5. Fan
2. Pump 6. Radiator
ENGINE TROUBLESHOOTING
Problems Possible causes Remedies
Engine does not start. 1. Battery partially discharged. Check and recharge battery. Replace
if necessary.
2. Battery terminal connections cor- Clean, inspect and tighten terminal

roded or loose. nuts. Replace terminals and nuts if
excessively corroded.
3. Injection pump timing incorrect. Adjust injection pump timing.
4. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If neces-
sary clean and dry the fuel tank.
5. No fuel in tank. Fill tank.
6. Fuel supply pump malfunction. Check and replace pump if neces-

sary.
7. Air in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air, then bleed system.
8. Starter motor faulty. Repair or replace starter motor.
9. Thermostarter faulty. Check and replace thermostarter if

necessary.
Engine stalls. 1. Idle speed too low. Adjust idle speed.
2. Irregular delivery from injection Check injection pump delivery on test

pump. bench.

4. Fuel filters clogged. Renew filter cartridges.

5. Incorrect valve clearances. Adjust valve clearances.
6. Burnt or cracked valves. Replace valves.
7. Air in fuel system. Check fuel lines, unions, supply
pump, filters and injection pump for
air, then bleed system.
8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)

Engine overheats. 1. Coolant pump malfunction. Overhaul pump or replace.
2. Thermostat faulty. Replace thermostat.
3. Radiator inefficient. Remove internal deposits by flushing.
Check for leaks and repair.
4. Deposits in cylinder head and Flush out coolant system.
crankcase coolant passages.
5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.
6. Coolant level low. Top up expansion tank with specified
coolant mixture.
7. Incorrect timing. Check and adjust.
8. Injection pump calibration incor- Calibrate pump on test bench to val-
rect -- delivering too much or too ues specified in calibration tables.
little fuel.
9. Air filter clogged. Clean filter unit and replace filter ele-
ment if necessary.
Engine lacks power and 1. Injection pump timing incorrect. Adjust injection pump timing.
runs unevenly.
2. Auto advance regulator in injec- Overhaul injection pump and adjust
tion pump damaged. on test bench to values specified in
calibration table.
3. Distributor journal worn. Overhaul injection pump and adjust
on test bench to values specified in
calibration table.
4. Irregular delivery from injection Overhaul injection pump and adjust
pump. on test bench to values specified in
calibration table.
5. All--speed governor damaged. Overhaul injection pump and adjust
calibration table.
6. Injectors partially obstructed or Clean, overhaul and calibrate injec-
damaged. tors.
(continued)

8. Fuel supply pump damaged. Replace fuel supply pump.
9. Incorrect valve clearances. Adjust valve clearances.
10. Cylinder compression low. Test compression and overhaul en-
gine if necessary.
ment if necessary.
12. Tie--rod in linkage between acce- Adjust to correct length.
lerator and injection pump incor-
rectly adjusted.
13. Maximum speed screw on injec- Adjust max. speed screw.
tion pump incorrectly adjusted.
Engine produces abnormal 1. Injectors partially obstructed or Clean, overhaul and calibrate injec-
knocking noises. damaged. tors.
2. Impurities accumulating in fuel li- Clean fuel lines and replace severely
nes. dented pipes. Clean injection pump if
necessary.
3. Injection pump timing incorrect. Adjust injection pump timing.
4. Crankshaft knocking due to ex- Re--grind crankshaft journals and
cessive play in one or more main crankpins. Fit oversize shell bearings
or big--end bearings or excessive and thrust washers.
endfloat.
5. Crankshaft unbalanced. Check crankshaft alignment and bal-
ance; replace if necessary.
6. Flywheel bolts loose. Replace any bolts that have worked
loose and tighten all bolts to the speci-
fied preliminary and angular torque
values.
7. Connecting rod axes not parallel. Straighten connecting rods, check
axes parallelism; replace con rods if
necessary.
8. Piston knock due to excessive Re--bore cylinder liners and fit over-
wear. size pistons.
9. Noise caused by excessive play Fit oversize gudgeon pin, re--bore pis-
of gudgeon pins in small--end and ton seats and small--end bushings.
piston bushings. or loose fit of Replace bushings.
small--end bushing.
10. Excessive tappet / valve noise. Check for broken springs or exces-
sive play between valve stems and
guides, cam followers and bores. Ad-
just valve clearances.
(continued)

Engine produces excessive 1. Maximum delivery of injection Calibrate pump on test bench to val-
black or dark grey smoke. pump too high. ues specified in calibration tables.
2. Injection pump delivery excessi- Adjust injection pump / engine timing
vely retarded or automatic advan- or check automatic advance regula-
ce regulator damaged. tor.
3. Injection pump delivery excessi- Adjust injection pump timing.
vely advanced.
4. Injectors partially or totally ob- Clean and overhaul injectors and ad-
structed or incorrectly adjusted. just pressure setting; replace if nec-
essary.
ment if necessary.
6. Loss of engine compression due Replace damaged parts or, if neces-
to: sary, recondition engine.
-- piston rings sticking;
-- cylinder liner wear;
-- worn or incorrectly adjusted val-
ves.
7. Damaged high--pressure fuel li- Inspect and replace if necessary.
nes.
Blue, grey--blue or grey-- 1. Injection pump delivery excessi- Adjust injection pump / engine timing
white smoke. vely retarded or automatic advan- or check automatic advance regula-
ce regulator damaged. tor.
2. Injectors obstructed or damaged. Clean and overhaul injectors and ad-
just pressure setting; replace if nec-
essary.
3. Oil leaking past piston rings due Replace damaged parts or, if neces-
to sticking rings or cylinder liner sary, recondition engine.
wear.
4. Oil leaking through the inlet valve Recondition cylinder head.
guides due to guide or valve stem
wear
5. Engine does not reach correct Replace thermostat.
operating temperature (thermo-
stat faulty).
Engine runs on after swit- 1. Engine stop solenoid damaged. Replace solenoid.
ching off.
2. All--speed governor damaged. Overhaul injection pump and adjust
calibration table.
Op. 10 001 10
ENGINE Removal--Installation
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Make sure that
no--one is standing in the vicinity of the load to be
lifted.
WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.
Proceed as follows.
1. Carry out Clutch operation 18 110 10, only remov-
al (see sect. 18).
27764
2. Remove the clogged air filter sensor connection
(1). 7
3. Disconnect the horn connection (1).
27765
8
4. Loosen the clamps (1, 2 and 3) and remove the
inlet manifold.
27180
9
5. Unscrew the band clamps and detach the upper
(2) and lower radiator hoses, detach the radiator
bracket (1).
27807
10
6. Position two fixed stands under the front axle sup-
port and under the engine. Attach the chains so
that the engine is balanced during hoisting and
position two wood blocks between the support
and the front axle, to prevent oscillation.
7. Loosen the front axle support retaining bolts (1).
8. Remove the engine from the axle--support unit.
9. To re--install the engine, proceed as follows.
WARNING
NEVER USE YOUR FINGERS OR HANDS. 27808
11
-- Apply the torque settings listed on page 20.
-- Re--install the front axle--support unit on the en-
gine.
-- Connect and secure the upper and lower radiator
hoses and the connecting bracket.
-- Fit and secure the inlet manifold.
-- Connect the horn and clogged air filter connec-
tions.
-- Carry out Clutch operation 18 110 10, only remov-
al (see sect. 18).
Op. 10 001 30 COMPRESSION TEST 6) Fit the dummy injector made from “Tools” on page
21, in place of the injector removed previously, inter-
In case of poor engine performance, in addition to posing the copper sealing washer.
checking the fuel injection system (injection nozzles
7) Connect the compression test instrument 291309
and injection pump), also test the compression on
and take readings while turning the engine over with
each cylinder.
the starter motor.
On engines in perfect working order, with the sump oil
DANGER at approx. 40 oC (104 oF) at sea level (760 mm --
29.92 in. -- of mercury) and at an engine speed of 200
Do not use matches, lighters, blow torches or any
form of naked flame as a source of light when inspect- to rpm, the compression should be 25.5 to 27.5 bar
ing the engine due to the presence of inflammable (369.9 to 398.9 psi).
fluids and vapour. 8) Test the compression on the other cylinders, re-
peating steps 4--5--6--7, bearing in mind that:
The minimum permissible compression on a used en-
Compression ratio gine is 21.6 bar (313.3 psi).
The compression ratio is a measure of the quantity of The maximum permissible compression difference
air drawn into the cylinder, and provides an indication between cylinders is 3 bar (43.5 psi).
of the efficiency of the sealing elements in the cylinder Every 100 meters (109.36 yards) above sea level cor-
(piston rings and valves). responds to a reduction in compression by approx.
Uniform compression in all the cylinders ensures that 1%.
they all perform an equal amount of work, provided
that each cylinder is injected with the same quantity
of fuel at the right time.
Low compression not only reduces engine perfor- CONSIDERATIONS:
mance, it also causes incomplete fuel combustion
due to the lack of available combustion air. Uniform compression
The engine therefore gives poor performance with Although high compression is important, it is more im-
excessive fuel consumption and, consequently, ex- portant for smooth engine running that compression
haust smoke and restriction of the exhaust passages. is uniform in all cylinders.
As the compression ratio also varies with the tem- Low compression readings
perature of the engine (cold engines produce lower
If extremely low pressure readings are obtained on
compression values than hot engines), the compres-
one cylinder it is advisable to repeat the test.
sion should only be tested when the engine is at nor-
mal operating temperature. Before testing this time, pour approx. one spoonful of
engine oil into the cylinder through the injector bore.
Compression should be tested using the compres-
sion test kit 291309, as follows: Turn over the engine a few times to distribute the oil
evenly over the cylinder walls, and then repeat the
1) Run the engine until it reaches normal operating test.
temperature.
If the second test readings are significantly higher,
2) Switch off the engine. the problem may be worn piston rings, out--of--round
3) Disconnect the lead from the engine stop electro- or damaged pistons or liners.
magnet on the injection pump in order to close the If the second test readings are not higher, the prob-
valve and block the flow of fuel to the injectors. lem will be the valves.
4) Remove the injector from the cylinder to be tested. On the other hand, if the second test reading shows
5) Turn the engine over a few times with the starter only a slight improvement, the problem will be due to
motor in order to expel any carbon residue. both the valves and the rings.
Op. 10 001 54
ENGINE Removal--Assembly
WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing
-- safety goggles, gloves and shoes.
Proceed as follows.
1. Unscrew: the thermostarter union (2), the inlet
line retaining unions (1) from the pump and the in-
jectors, and detach the piping (1).
27770
12
2. Unscrew: the connecting lines (2) to the injection
pump and the support retaining bolts (1), remove
the pump and the fuel filter.
27771
13
3. Unscrew: the hydraulic pumps piping retaining
bolts (2), the oil filter (1) retaining bolts, complete
with the support, from the engine and remove.
27772
14
4. Unscrew the retaining bolts and remove the hy-
draulic pumps from the lift (2) and services (1),
which completes the piping (3).
27773
15
5. Unscrew the retaining bolts and remove the start-
er motor (1).
27774
16
6. Unscrew the retaining bolts and remove the cover
(3), loosen the retaining nut (2) on the injection
pump (1) and remove from the opposite side.
27775
17
7. Unscrew the retaining nuts and remove the fuel
pump (1).
27776
18
8. Unscrew the retaining bolts and remove the ex-
haust silencer (1) complete with the vertical pipe.
On models with horizontal exhaust pipes, remove
when disassembling the engine.
27777
19
9. Unscrew the retaining bolts, remove the alterna-
tor (1) and recover the drive belt.
10. Remove the engine oil filter (2).
27778
20
11. Unscrew the retaining bolts and remove the ex-
haust manifold (1).
27779
21
12. Unscrew the retaining bolts and detach the cool-
ant pump hose(1).
27780
22
ant pump (1) complete with fan (2).
27781
23
ant pump support (1).
27782
24
15. Unscrew the retaining bolts and disconnect the
thermostatic valve unit (2) complete with bracket
(1).
27783
25
16. Unscrew the retaining bolts and remove the inlet
manifold (1).
27784
26
17. Remove the injector mounting nuts, the underly-
ing spherical washers, then the supports and the 1
injectors themselves.
18. Remove the rocker cover bolts (1), washers and
seals, and then the rocker cover (2) and its gas-
ket.
25098
27
19. Remove the rocker shaft retaining bolts (2), then
remove the entire rocker shaft assembly (1).
1 2
25099
28
20. Remove the valve collets (1) and extract the
pushrods (2). 1 2
25100
29
21. Unscrew the cylinder head bolts (1) and remove
the head using a hoist and lifting hook 290740.
22. Remove the cylinder head gasket.
25101 1
30
23. Unscrew the sump pan retaining bolts (4) and re-
move the sump pan using a hoist, lifting hook 1 2
290740 and lifting chain with eyeholes.
24. Remove the half--gaskets (1) and (3) between the
crankcase and sump pan and the gasket (2) be-
tween the timing gear carrier and sump pan.
3
25104
31
25. Remove the gasket (1) between the flywheel car-
rier and the sump pan.
NOTE: When relocating gaskets (1) and (2, fig. 31),

apply RHODORSIL CAF1 silicone sealing compound
to the mating surfaces.
25105
32
26. Remove the rotating counterweight oil seal O--
ring (1) installed on the crankcase mating sur-
face.
25106
33
27. Unscrew retaining bolts (1) and remove the com-
plete oil pump.
1
25107
34
28. Unscrew the retaining bolts (2) and remove the
crankshaft pulley (1). 1
25108
35
29. Straighten the lock tab, securing the crankshaft
against rotation and unscrew nut.
25109
36
30. Pull the pulley hub off the crankshaft using tool
291504 (1) and recover the woodruff key.
25110
37
31. Unscrew the retaining bolt (1) and remove the
timing cover and gasket.
25111
38
32. Unscrew the retaining bolts and remove the lift
pump drive gear carrier (1).
1
25112
39
33. Remove the circlip (1) and recover the thrust
washer and the intermediate gear (2):
1 2
NOTE: When refitting the intermediate gear see en-
gine timing instructions on page 49.
25113
40
intermediate gear journal.
1
25114
41
35. Unscrew the retaining bolts (2) and withdraw the
camshaft (3) complete with the camshaft gear (1)
and the end plate (4). 1
4
25115
42
36. Remove the circlip (1) and the thrust washer, and
withdraw the gear with fuel supply pump cam-
shaft (2) from the opposite side.
NOTE: This gear transmits drive to the injection

pump gear. On re--assembly see timing instructions 1
on page 49.
25108
43
timing gear case.
25109
44
38. Renew the O--ring seal (1) installed in the lift
pump drive shaft lubrication line.
39. Remove the crankcase -- timing gear case gas-
ket.
25118
45
40. Rotate the engine through 90_, on the stand. Un-
screw the big--end cap bolts (2) and recover the
big--end caps (1) with their half shell bearings. 1
25119
46
41. Slide the pistons (1), complete with rings, gud-
geon pins and connecting rods, out of the cylinder
linings.
25108
47
42. Rotate the engine on the stand through 90_ back
to the horizontal position. Unscrew the flywheel
bolts and remove the flywheel with the aid of a 1
hoist and hook 290740.
43. Unscrew the retaining bolts and remove the rear
oil seal carrier (1) complete with gasket.
25109
48
44. Unscrew the main bearing cap bolts (1), and re-
move the main bearing caps with relative bearing
shells, and recover the thrust washers located on
the penultimate main bearing, as shown in the fig-
ure.
45. Lift the crankshaft clear of the crankcase using a
hoist and nylon sling. Recover the bearing shells,
thrust washers and tappets. 1
25122
49
46. Turn the engine through 180_ on the stand
290090 (2). Attach the lifting chain with eye holes
to the crankcase, as shown in the figure. Raise 1
the hook 290740, unscrew the bolts securing the
crankcase to the stand (2) and mounting bracket
(3) from set 293860.
47. Lift the engine clear of the stand.
48. Unscrew the retaining bolts and remove the rear 3 2
crankcase housing (1) and its gasket.
25123
50
GENERAL NOTES AND INFORMATION
-- After dismantling the engine, clean all parts care-
fully.
-- To re--assemble the engine, carry out the disman-
tling operations described on pages 34 to 43.
-- The following pages 44 to 50 concern assembly
operations that require special attention.
-- Tightening torques are specified on page 20.
IN ADDITION, REMEMBER TO:

-- Replace all seals and gaskets at each complete
or partial engine rebuild.
-- Lubricate all rotating parts and oil seals with en-
gine oil prior to installation.
-- Lubricate the oil filter mounting seal prior to fitting
the filter.
WARNING
fingers between parts. Always use suitable tools to
align holes in parts.
Wear suitable safety clothing -- safety goggles,
gloves and shoes.
MOUNTING THE TAPPETS AND DRIVE

SHAFT WITH MAIN BEARING CAPS, BEAR-
INGS AND THRUST RINGS:
CHECKING AXIAL PLAY ON CRANK SHAFT
(Disassembly operations 44 to 45)
Proceed as follows:
-- Install the tappets in their crankcase bores.
-- Lubricate the main bearing seats with engine oil

and install the half--shell bearings (3). 1
-- Stick the semi--circular thrust washers (1) to both 3 2

25109
sides of the penultimate main bearing with
grease. 51
-- Lubricate the upper surfaces of the main bearing
shells with engine oil and lower the crankshaft (1)
into position, taking care not to dislodge the 1
semi--circular thrust washers installed previously.
24718
52
-- Lubricate the crankshaft journals with engine oil
and fit the main bearing caps (3) with the half--
shells (4), fitting the top semi--circular thrust 1 2 3
washers (2) to the penultimate bearing cap.
-- Rotate the crankshaft (1) a few times to allow the
parts to settle into position.
-- Insert the main bearing cap bolts and screw in un-
til the head of the bolt is up against the cap.
4
25108
53
-- Tighten all cap bolts (1) to a torque of 80 Nm (59
lfb.lb). 1
24720
54
-- Using tool 292248 (2) tighten each cap bolt (1)
through a further 90o. 1 2
24744
55
-- Check that the crankshaft endfloat does not ex-
ceed the value specified on page 13.
24760
56
MOUNTING THE REAR COVER WITH
CRANKSHAFT SEAL AND ENGINE FLY- 1
WHEEL
(Disassembly operation 43) 3

Proceed as follows: 2
-- Fit the rear oil seal carrier (3) with the outer seal.
Tighten the retaining bolts (2) to the torque speci-
fied on page 20. Using a feeler gauge (1), check
that the crankshaft flange is coaxial with the carri- 24752
er. 57
Oil leakage from the crankshaft rear oil seal (part
number 98461686) will result if the seal is not handled
or installed correctly. The correct handling and
installation procedures are as follows:
1. The seal that was originally installed had a 6mm
(0.236″) gap, 1, between the seal housing, 2, and 2
the molded plastic insert, 3.
20026008
58
IMPORTANT: The seal is preassembled with a

protective molded plastic insert.
Carefully handle the seal by the molded plastic insert
only.
The insert is to protect the seal from any damage
during parts stock and during installation.
The protective molded plastic insert MUST NOT be
removed or rotated in the seal prior to installation.
The insert should only be removed after the new seal
has been completely installed as detailed in these
instructions.
2. The machined sealing surface area of the
crankshaft MUST NOT be cleaned using any
type of abrasive paper.
3. The new seal lip should never be positioned in the
exact same location on the crankshaft as the
previous seal that was removed. This is to
prevent the new seal lip from riding in the wear
groove made by the previous seal lip.
4. The first replacement seal should be installed
with a gap, 1, of 3.8 to 4 mm (0.150 to 0.157″)
between the seal housing, 2, and the molded 2
plastic insert, 3.
20026009
59
5. The seal, complete with the insert, must only be
installed using the special made tools described
below.
NOTE: The spacer is used for the correct clearance
gap of 3.8 to 4 mm (0.150 to 0.157”). The installer
bushing is used to install the seal into the housing.
It is recommended to manufacture the special tools

prior to requirement. (See dimensions for the spacer
and installer bushing as shown)
1. Spacer ID: 135.5 to 136 mm (5.335 to 5.354″)

20026010
2. Spacer Width: 3.8 to 4 mm (0.150 to 0.157″)
3. Spacer OD: 145 mm (5.709″) 60
4. Installer Bushing: 115 mm (4.527″)
5. Installer Bushing Width: 30 mm (1.181″)
6. Installer Bushing OD: 129 mm (5.079″)
Seal Installation
6. Lightly oil the crankshaft seal area with new
engine oil.
7. Install the spacer onto the molded plastic insert.
Use the installed bushing to push the seal into
position in the seal housing.
8. Ensure that the seal is installed evenly around the
full circumference (the spacer should be against
the molded plastic insert and the housing all the
way around).
NOTE: The molded plastic insert should not be
removed until the seal is correctly positioned.
IMPORTANT: The engine MUST NOT be started
within 24 HOURS of the seal installation and plastic
insert removal. This is required to allow the seal to
expand and settle onto the crankshaft after the
molded plastic insert is removed.
-- Fit the flywheel and tighten the retaining bolts (1)
to a torque of 40 Nm (30 lfb.lb).
24762
61
-- Using tool 292248 (1), tighten each flywheel bolt
(2) through a further 60o.
1
24763
62
MOUNTING THE PISTONS COMPLETE WITH

RINGS, PINS, CONNECTING RODS, BIG END
CAPS AND BEARINGS -- CHECKING PRO-
TRUSION IN RELATION TO CYLINDER
BLOCK FACE
(Disassembly operations 40 and 41)
Proceed as follows:
-- Lubricate pistons, rings and cylinder liners with en-
gine oil prior to fitting.
-- Using the piston ring pliers 291160 fit the piston
25163
rings. Make sure that the piston ring gaps are offset
at 180o. 63
-- Fit piston ring clamp 291048 (1) to compress the
rings (2), making sure that the piston ring gaps re-
main in the positions specified in the previous point.
-- Insert the piston / connecting rod into the cylinder
liner, checking that the connecting rod number 1 2
corresponds with the cylinder number and that
the number stamped on the connecting rod is fac-
ing away from the camshaft.
-- Fit the big--end caps (1), complete with shells, to
the crankpins and tighten the cap bolts (2) to a
torque of 40 Nm (30 lfb.lb).
25164
64
-- Using tool 292248 (1), tighten each big--end cap
bolt (2) through a further 60o. 1 2
25165
65
-- Rotate the engine on the stand through 180o and
clean the upper face of the cylinder block.
Bring the pistons (2), up to TDC and, using a dial 1 2
gauge with a magnetic base (1), check that the
piston protrusion from the cylinder block face is
within the tolerance limits specified on page 13.
25166
66
SYNCHRONISING THE TIMING GEARS
(Disassembly operations 32 to 36)

Proceed as follows:
-- Remove the cover of the flywheel housing in-
spection window and its gasket.
25167
67
-- Turn the drive shaft so as to bring cylinder No. 1
to TDC (compression stroke).
Look through the inspection window to check that
the notch in degrees aligns with the index mark,
according to the type of BOSCH pump installed
on the tractor (see pages 6--8--10).
26107
68
-- Fit the timing gears, making sure that the various
reference marks indicated by the arrows in the
figures are aligned.
25169
69
REFITTING THE BOSCH INJECTION PUMP
(Disassembly operations 6)
-- Fit the BOSCH injection pump and proceed with
the injection pump timing, as described on page
86.
1
25181
70
FITTING THE CYLINDER HEAD GASKET
1
(Disassembly operation 22)
Proceed as follows:
-- Before fitting the cylinder head, carefully clean
and degrease the mating surface of the cylinder
block. Locate the cylinder head gasket (1) with
the word ALTO uppermost.
25173
71
FITTING AND TIGHTENING THE CYLINDER
HEAD

Proceed as follows:
-- Lower the cylinder head onto the block and screw
in the cylinder head bolts (1, fig. 73) so that the
heads are brought into contact with the cylinder
head.
25174
-- Tightening sequence for cylinder head bolts (1,
fig. 73) on 4--cylinder engines to be followed for
tightening stages (A = fan end). 72
-- Tighten the bolts (1) to a torque of 70 Nm (51
lfb.lb) in the sequence indicated above (1st
stage).
-- Check the torque of all the bolts in the sequence
indicated above (2nd stage).
25176
73
-- Using the angular tightening tool 292248 (1) tight-
en each bolt (2) in sequence through 90o (3rd 1
stage) and then through a further 90o (4th stage)
in the sequence indicated above.
2
25177
74
ADJUSTING VALVE / ROCKER ARM
CLEARANCE 1
-- Before refitting the rocker cover, adjust the valve
clearances as described on pages 76 and 77.
-- Tighten the rocker arm adjuster screw locknuts
(1) to the torque specified on page 20.
25178
75
FITTING THE INJECTORS
Proceed as follows:
-- Insert the injectors (2) in their respective bores.
-- Position the injector support brackets and fit the
spherical washers.
-- Screw the bracket retaining nuts (1) up to the
spherical washers then, using a torque wrench, 1
tighten to the torque specified on page 20 in two
stages:
1st stage, tighten nuts to 10 Nm (7 lfb.lb); 2
2nd stage, tighten nuts to 25 Nm (19 lfb.lb). 25179
-- Tighten the leak--off pipe unions.
76
-- Tighten the high--pressure fuel line unions.
ADJUSTING BELT TENSION ON THE
COOLING SYSTEM
(Disassembly operations 9)
NOTE: Tension the belt correctly, as shown on page

68.
CHECKS, DIMENSIONS AND REPAIRS --
CYLINDER BLOCK AND CYLINDER LINERS)
WARNING
Clean all parts carefully before proceeding with the

operations described below.
NOTE: Cylinder liner dimensions must only be mea-

sured when the liner is installed in the cylinder bore,
as they are subject to deformation when not fitted.
Check line wear as follows:

-- measure the inside diameter in the area swept by
the piston rings (X, fig. 79);
-- measure the inside diameter at the upper and
lower ends of this area both parallel to the crank-
shaft centre line (a) and perpendicular to the
crankshaft centre line (b);
-- compare these measurements to determine liner
ovality and taper.
To check piston running clearance, measure the I.D.
of each liner in the area (Z, fig. 79) only along the axis
(b) perpendicular to the crankshaft centre line.
If ovality or taper exceed 0.12 mm (0.0047 in.) or pis-
ton coupling play exceeds 0.3 mm (0.0118 in.), re--
bore and grind (or change) the liners, to bring them up
to one of the sizes shown in the table on page 12.
Then pair up the cylinder liners with the pistons of the
same dimensions (see page 12).
NOTE: If one of the liners is re--bored, all of the liners

in the engine must also be re--bored to the same over-
size.
After boring, the 0.5 mm (0.0197 in.) a 30o champfer

must be restored on the liner (1). 1
25307
In case of replacement, remove and install the liners

in cylinder block cold using a press as follows: 77
-- Press the worn liner out of the block operating
from the bottom of the crankcase using the ap-
propriate plate.
-- Check the ovality of the bore in the block and re--
bore if necessary to 0.2 mm (0.0078 in.) oversize.
-- Press--fit the new liner (0.2 mm -- 0.0078 in. --
oversize if necessary) from the top of the block,
using the appropriate plate.
-- Re--bore and ream the liner to the specified I.D.
(see page 12).
25308
78
25310
79
Standard dimensions (mm) of cylinder liners and bores in the cylinder block and positions for checking liner wear
A. Positions of dial gauge to measure liner I.D. E. Area for measurement of inside diameter of worn
B. Positions of dial gauge to measure liner I.D. liner (area swept by piston rings) to determine ovality
C. Dimension to obtain after press--fitting and reaming and taper (measure along axes a and b, respectively
of liner. parallel and perpendicular to the crankshaft).
D. Area for measurement of inside diameter of used 1. Planes of measurement of the internal diameter of
liner to determine piston running clearance (mea- new and ground liners, along the two perpendicular
sured along axis b perpendicular to crankshaft). axes (A, B).
CRANKSHAFT, MAIN BEARINGS AND
FLYWHEEL
WARNING
Crankshaft
Carefully inspect the crankshaft. Any cracks, even
slight, will necessitate replacement of the crankshaft.
Inspect the crankshaft journals and crankpins; slight
scoring or seizure marks can be removed with very
fine grade emery cloth.
If scoring, ovality or taper exceeds 0.05 mm (0.0020
in.), the crankshaft will have to be reground.
Measure journal diameter to determine the nearest
undersize (see page 13).
After regrinding, restore the journal and crankpin
rounds and fillets as shown in the details below, and
check that:
-- main bearing journal and crankpin ovality does
not exceed 0.008 mm (0.0003 in.);
25311
-- main bearing journal and crankpin taper does not
exceed 0.01 mm (0.0004 in.); 80
81
Standard dimensions (mm) of main bearing journals and crankpins, main bearings and semi--circular thrust washers
A. Crankpin rounds and fillets. C. Rounds and fillets of crankshaft journal with thrust
B. Normal crankshaft journal rounds and fillets. washers.
-- with the crankshaft resting on parallel gauge crankpins and the crankshaft centreline are equal
blocks, the maximum misalignment of the main to a tolerance of ± 0.10 mm (0.0039 in.);
bearing journals does not exceed 0.10 mm -- the run--out measured with the dial gauge contact
(0.0039 in.) (C) fig. 82; point resting on surface (A) or (B) does not ex-
ceed the value specified in the table on page 14;
-- the centrelines of each pair of crankpins lie in the
same plane as the main journal centrelines, with -- the oil plugs seal against an oil pressure of 14.7
a maximum deviation of ± 0.25 mm (0.0098 in.) bar (213.2 psi);
as measured perpendicularly to the same plane; -- if new plugs are fitted, punch--lock in position and
re--check oil tightness with the system pressur-
-- the distances between the outer surfaces of the ised.
25314
82
Maximum tolerance for alignment of main bearing journals and crankpin relative to crankshaft centreline and
alignment of crankpins relative to main bearing journals
A. Dial gauge contact point positions for checking per- tering of flywheel mounting flange.
pendicular run--out of flywheel mounting flange. C. Maximum permissible main bearing journal alignment
B. Dial gauge contact point positions for checking cen- deviation.
Bearings
Check the clearance between the crankshaft journals
and the bearing shells using a calibrated wire gauge 1 2
as follows:
-- make sure that all parts are perfectly clean and
remove all traces of oil; 3
-- locate the half--shells in their respective seats (5);
-- install the crankshaft;
-- position lengths of calibrated wire (6) on the
crankshaft journals (4) in correspondence with
the crankshaft centreline (6);
6 5 4
-- fit the caps (1) complete with half--shells (2) to the 25316
respective journals; 83
-- lubricate the screws (4, fig. 3) fixing the main
bearing caps with engine oil and tighten them to
the prescribed torque using a torque wrench (see
page 20);
Main bearing cap bolts (4, fig. 3)

If the bolts are to be re--used, check that diameter d
(measured in area a shown in the figure) is greater
than 13.5 mm (0.5315 in.); if not, replace the bolts.
25318
84
-- Remove the caps and determine the bearing
clearance by comparing the width of the cali-
brated wire at the widest point against the scale
printed on the packet (3) fig. 83 containing the
wire.
-- After refitting the crankshaft and the bearing caps
and bolts, check crankshaft endfloat, using a dial
gauge (1), at the penultimate bearing.
-- If the endfloat exceeds the specified value (see
page 13), replace the existing thrust washers with
oversize washers.
25317
1
85
Flywheel
The flywheel is fixed to the crankshaft flange by

means of self--locking bolts. The starter ring gear is
force--fitted after pre--heating to the register on the
engine side of the flywheel.
If the ring gear is to be replaced, heat in oil to 80o to

90o C before fitting, and position with the bevel on the
teeth facing inward towards the starter motor.
The flywheel mounting holes are offset so that the fly-
wheel can only be mounted in one position.
If the flywheel is overhauled, the friction surfaces can
be reground, re--facing by 1 mm (0.0394 in.) in rela-
tion to the nominal thickness of 38.5 ± 0.2 mm
(1.5157 ± 0.0079 in.).
Once terminated, the external re--facing will need to
be re--set to 0.5 mm (0.0197 in.), as shown in the fig-
ure.
25714
86
-- Lubricate the engine flywheel fixing screws (3, fig.
3) with engine oil, and tighten them to the pre-
scribed torque using a torque wrench (see page
20);
Flywheel bolts (3, fig. 3)
If the bolts are to be re--used, check that diameter d 25319

than 11.5 mm (0.4528 in.); if not, replace the bolts. 87
CONNECTING RODS
WARNING

Check that the bushings in the connecting rod small

ends are tight in their bores and are flush with the
sides of the rods.
If necessary, replace the bushings and ream after fit-

ting to the specified diameter (A) described in the fig-
ure.
25320
Dimensions (mm) of standard connecting rods,

bearing shells, bushings and gudgeon pins
A. Dimensions to obtain by reaming after fitting bush-

ings -- L, M. Oil ports. 88
Check parallelism of small end and big end axes.

Maximum permitted tolerance is ± 0.07 mm (0.0028
in.) measured at 125 mm (4.9213 in.) from the longi-
tudinal axis of the connecting rod.
Slightly twisted con rods can be straightened using a

press. Severely deformed rods should be replaced.
New con rods must be marked with the number of the

cylinder in which they are to be fitted. Check that the
difference in weight of the connecting rods in the
same engine does not exceed 25 grams.
25321
Also check that the oil ways (L and M, fig. 88) are not
obstructed by scale or impurities. 89
PISTONS
WARNING
Handle all parts carefully.
Do not put your hands or fingers between parts.
gloves and shoes.

Determine the degree of piston and liner wear in the
manner described on pages 12 and 15 and the figures
below.
If the piston running clearance exceeds 0.30 mm
(0.0118 in.), re--bore and ream the liners and fit over-
size pistons and rings (see pages 12 and 15).
In case of piston replacement, Check that the differ-
ence in weight between pistons in the same engine
does not exceed 20 grams.
Check that the piston ring groove clearance (b) fig.
90 and the end gap (c) are within the tolerances spe-
cified on page 15. If the end gap is less than that spe-
cified, correct by grinding the ends of the piston ring.
A B
C
25322
90
Checking pistons and rings
A. Checking piston diameter at a distance (L) from the C. Checking the end gap with ring in cylinder bore.
base of the skirt. D. Distance from the base of the piston skirt: 57 mm
B. Checking piston ring groove clearance. (2.2441 in.).
25323
91
Dimensions (mm) of standard pistons, gudgeon pins and rings
A. Measurement to be obtained with ring inserted in B. Piston diameter measured at 57 mm (2.2441 in.) from
cylinder bore. the base of the skirt.
To remove or fit piston rings (1) use pliers 291160 (2).
Fit rings in grooves in the order indicated in fig. 91.

1
When fitting pistons on connecting rods, check that
the clearance between the gudgeon pin and its bore
in the piston is within the tolerance specified on page
15.
2
25324
92
Check that the piston / connecting rod assembly is
perfectly square.
If not, replace parts causing the problem.
25108
93
Note:
1
-- Oil the pistons, rings and liners before inserting
the pistons in their bores.
-- Before fitting the ring clamp 291048 (1) to com-
press the rings for piston (2) insertion in the liner,
check that the ring end gaps are offset by an
angle of 180o.
2
25326
94
Big end cap bolts (5, fig. 3)
If the bolts are to be re--used, check that diameter d

(measured in the area a shown in the figure) is greater
than 10.5 mm (0.4134 in.); if not, replace the bolts.
NOTE: It is advisable to replace the big end cap bolts 25327

each time the connecting rods are dismantled.
95
CAMSHAFT, TAPPETS AND VALVES
WARNING

Valves
Use tool 291050 for valve removal and installation.
In the case of minor sealing faults, the valves and
their seats in the cylinder head may be re--faced using
a pneumatic grinder or universal grinder. In case of
more serious defects, re--face the seats and grind the
valves as shown in the relative chapter.
After grinding, check that the step below the valve
contact band is no less than 0.5 mm (0.0197 in.).
Dimensions (mm) of valves and valve guides
A. Inlet.
B. Distance to be obtained by reaming the fitted
valve guide.
S. Discharge. 96
Tappets
Check that the tappets slide freely in their bores with-

out excessive play.
In the case of excessive tappet--to--bore clearance,
re--bore the seats and fit oversize tappets (see page
16).
Pushrods must be perfectly straight, and the concave
surface with the rocker arm adjuster screw must not
show signs of seizure or excessive wear, otherwise
the rod must be replaced.
25329
In case of re--facing of the contact surfaces, remove
as little material as possible. 97
Camshaft
Position the camshaft on two parallel V blocks and,
using a dial gauge with 1/100 mm scale, check that
journal run--out relative to the axis of rotation does not
exceed 0.02 mm (0.0079 in.).
If run--out does not exceed 0.2 mm (0.0079 in.), the
camshaft may be straightened using a press; other-
wise replace the camshaft.
Check cam lift using a dial gauge, which should be as
follows:
-- 5.97 mm (0.2350 in.) inlet valve; 25328
-- 6.25 mm ()0.2461 in.) exhaust valve. 98

Replace worn bushings using suitable extractors and
drifts, and ream to obtain the inside diameter indi-
cated in figure 98.
25331
99
Dimensions (mm) of camshaft journals and relative seats in cylinder block
Note -- The value indicated for the bushing inside diameter refers to the fitted part.
Valve timing check
To check the valve timing after dismantling/assembly

or overhaul of the valve timing gear, proceed as fol-
lows:
Check that the timing reference marks on the timing

gears are aligned as indicated on page 49.
Provisionally set valve clearances to 0.45 mm

(0.0177 in.).
Turn the crankshaft and, using a graduated timing

disk, check that valves open and close and the angles
indicated in the timing diagram.
On completion of the timing check, set the valve

clearances for normal running, as specified on pages
76 and 77.
Valve timing diagram.
A. Fixed advance (*).

1. TDC.
25333
2. BDC.
3. Inlet.
4. Discharge.
5. Injection. 100
(*) See page 2.

CYLINDER HEAD
WARNING
-- safety goggles, gloves and shoes. 1 2
Use valve spring compressor 291050 to remove and

refit valve springs.
Check that the cylinder head mating surface is flat us-
ing a straight edge (2) and feeler gauge (1).
If deviations of more 0.15 mm (0.0059 in.) are found,
the head must be refaced.
25108
NOTE: remove as little material as possible: the max- 101

imum depth of material that can be ground from the
cylinder head is 0.5 mm (0.0197 in.).
Using a dial gauge with magnetic base (1), check the

run--out of the valve head (2) in the guide and the 1 2
clearance between the valve stem and guide.
If the clearance exceeds the specified value (see

page 18), replace the valve and, if necessary, the
valve guide.
25940
102
VALVE SEATS IN CYLINDER HEAD --
Re--facing
1
WARNING
1. If the valve seats need re--facing to improve valve

sealing, use the universal valve grinder (1) and 25343
remove as little material as possible. 103
Dimensions (mm) of valve seats and valve guides.

A. Inlet.
B. Depth of taper.
S. Discharge.
(B)
25344
104
LUBRICATION SYSTEM
WARNING
1

operations described below. 2
OIL PUMP -- Overhaul 3

To access the oil pump, remove the sump pan.
When servicing the pump, check component wear
against the dimensions specified in the table on page 4
19.
In case of replacement, note that the drive shaft (3)
and drive gear are supplied ready assembled, with 5
the gear hot force--filled on the shaft.
Cross--sectional view of engine lubricating oil pump,

models TN 55 and TN 65 25354
1. External drive gear.

2. Bushing.
3. Drive shaft and gear.
4. Driven shaft and gear.
5. Pressure relief valve. 105
Cross--sectional view of engine lubricating oil pump,

model TN 70 and TN 75 1
1. Pressure relief valve.
2. Spring.
3. Pump body. 2
4. Internal gears.
4 3
26109
106
OIL FILTER -- Replacement CHECKS, DIMENSIONS AND REPAIRS --
COOLING SYSTEM
The oil filter (3, fig. 5) is of the full--flow, integral paper
cartridge type, and is installed on the pump delivery Clean all parts carefully before proceeding with the
line. operations described below.
Should the line become clogged, the safety valve (2) The cooling system is fitted with a permanent coolant
will open to allow the oil to by--pass the filter, thus en- mixture consisting of water and “AMBRA AGRIFLU”
suring that the engine continues to be lubricated, al- antifreeze (up to 50% in volume). This mixture pre-
though with unfiltered oil. vents freezing down to the following temperatures:
Replace the cartridge periodically (every 400 operat-

ing hours), remembering to: Degrees oC --8 --15 --25 --35
% in volume of
-- oil the outer part of the seal in contact with the ”AMBRA 20 30 40 50
mounting on the crankcase; AGRIFLU”
-- screw on the new cartridge until the seal is up

This mixture also has anti--oxidant, anti--corrosion,
against the mounting;
anti--foaming and anti--scaling properties to ensure
-- tighten the cartridge, by hand only, through a long--term protection of the cooling system.
further 3/4 turn. The same mixture can be kept in the cooling system
for a maximum of 2 years or 1600 operating hours,
whichever comes sooner, after which it must be
changed.
LOW OIL INDICATOR -- Functional checks
RADIATOR -- Flushing and checks
The indicator consists of a control switch (4, fig. 5) Two valves are built into the radiator cap, one com-
and a red warning lamp on the dashboard, which illu- pression valve and one depression valve. Check the
minates in the following conditions: correct operation of the valves periodically.
When overhauling, remove deposits of lime scale in
-- low oil pressure (the warning lamp also illumi- the radiator by means of a solution of water and
nates in normal conditions, without signifying a descaling agent in the proportions shown on the
fault, when the engine is hot and idling at low container.
speed);
It is never advisable to limit flushing to the radiator
-- control switch malfunction. only -- always extend this operation to the entire cool-
ing circuit. Top up the engine with the solution referred
to above.
If the red lamp fails to illuminate when the engine is
stopped and the ignition switch is turned to the power Run the engine for about an hour (with the engine off)
ON position, the possible causes are: in order to drain the solution through the drain plug.
-- blown fuse; If the system is leaking, check the radiator seal by im-
mersing it in a tank of water at a temperature of 20 to
-- blown lamp; 40 °C, blowing air into the radiator at a pressure of
0.98 bar (14.2 psi) for approx. two minutes (repeat the
-- interruption in wire to the control switch. test at least three times).
COOLANT THERMOMETER -- Testing
If malfunction is suspected, immerse the bulb of the

thermometer in water and check the readings against
a test thermometer (repeat the test a number of times
with different water temperature to be sure).
THERMOSTAT -- Replacement
The thermostat (1, fig. 6) is fitted in the cylinder head

coolant outlet union.
The thermostat cannot be adjusted and therefore
must be replaced if it does not meet the temperature
specifications in the table on page 3.
COOLANT PUMP AND ALTERNATOR

DRIVE BELT
Tension adjustment Op. 10 414 10
The fan/coolant pump/alternator drive belt is ten-

sioned correctly when it deflects 10 to 11 mm (0.3937
to 0.4331 in.) when a force of 78 to 98 N (8 to 10 kg
-- 17.64 to 22.05 lb.) is applied at the mid--point of the
run between the alternator and coolant pump pulleys.
Check the tension using the belt tension tester

296118. Adjust tension if necessary as follows:
1
2. slacken the nut (1) securing the alternator to the
tensioner bracket;
3. move the alternator to achieve correct belt ten-

sion, then tighten nut (1).
Note -- when fitting a new belt, check the tension

22631
again after one hour of running.
107
Op. 10 101 53
VALVE GUIDES Replacement
DANGER
equipment.
means of suitable slings and hooks.
Make sure that no--one is standing in the vicinity of the
load to be lifted. 1
WARNING
With the cylinder head on the test bench, proceed as

follows:
1. Enlarge the bore of the valve guide to be fitted,
using twist drill 294027. 25334
2. Place the cylinder head on a suitable support and
remove the valve guide to be replaced, using drift
291046 (1). 108
3. Turn the head upside down, and force fit the new
valve guide with the enlarged bore, using drift
291046 (2) and bush 293231(1).
25335
109
4. Ream out the valve guide bore (1) using reamer
291177 (2).
25336
110
NOTE: when replacing exhaust valve guides, pro-
ceed with the following operations.
5. Measure the distance (L) between the cylinder
head face and the base of the valve guide, using
a calliper gauge and the special plate (1) on tool
294028. 1
The depth of taper milling is given by:
B -- L = C
where:
B = depth of taper relative to cylinder head face (see
fig. 142). 25337
L = distance measured between cylinder head face 111

and valve guide base.
C = depth of taper milling.
Example
B = 43.1 to 43.6 mm (1.6968 to 1.7165 in.).
L = 34 mm (1.3386 in.). Distance measured.
C = (43.1 to 43.6) -- 34 = 9.1 to 9.6 mm;
[(1.6968 to 1.7165) -- 1.3386 = 0.3583 to 0.3780 in.].
Depth of taper milling.
6. From the upper side of the cylinder head, fit guide

bush (1) of tool 294028 on the guide valve to be
milled (2).
1 2
25109
112
7. Slide the cutter (1) of tool 294028, complete with
depth stop (2), into the previously located guide
bush until the cutting head is in contact with the
valve guide.
1
2
25339
113
8. Position the plate (3) of tool 294028 flush against
the cylinder head face and slide the depth stop (2)
up to the plate. Measure the distance (A) between
the depth stop and the end of the cutter shank (1). 1 2 3
25340
114
9. Position the depth stop (1) at a distance of (D) =
35.9 to 36.4 mm (1.4134 to 1.4331 in.) from the
end of the cutter shank and fix in place with its set
screw.
Distance (D) is given by:
D = A -- C
1
where:
D = the distance that determines the end of the taper
milling.
A = the distance between the end of the cutter shank
and the depth stop, with the plate flush against the 25341
cylinder head.
115
C = the depth of taper milling.
Example
A = 45.5 mm (1.7913 in.).
C = 9.1 to 9.6 mm (0.3583 to 0.3780 in.).
D = 45.5 -- (9.1 to 9.6) = 35.9 to 36.4 mm;
[1.7913 -- (0.3583 to 0.3780 in.) = 1.4134 to 1.4331 in.].
10. Turn the cutting tool (2) until the plate (3), is
brought up to the cylinder head face by the depth
stop (1). 1 2
NOTE: before fitting the cylinder head, clean thor-
oughly to remove all residue from the milling opera-
tion.
25342
3
116
Op. 10 101 60
INJECTOR SLEEVES -- Replacement
WARNING
1. If the cylinder head face has been reground,

check the injector stand--out is within the toler-
ance limits specified on page 18.
Checking injector and valve height relative to the
cylinder head face.
a. Checking injector stand--out (see page 18).
b. Checking valve stand--in: 0.7 to 1.0 mm (0.0276 to
0.0393 in.) (max. permissible stand in = 1.3 mm; 25345
0.0511 in.). 117

If injector stand--out exceeds the specified limit, re-
place the injector sleeve using tool kit 293270, pro-
ceeding as follows:
2. Set distance (A) on tap (3) 292240 to 9 mm

(0.3543 in.) by means of ring nut (5) and fix the
ring nut in position by tightening the set screw (4).
3. Cut an internal thread in the sleeve (2) to be re- 1 2
moved using tap 292240 (3) M 12 x 1.75, making
sure that the thread is cut only in the sleeve. 3
4. Fit tool 293784 (2, fig. 120) to the injector mount-
ing studs on the cylinder head by means of nuts 4
(3) (M 8 x 1.25).
5. Screw part (11, fig. 120) fully into the previously 5
cut thread and turn nut (1) to withdraw the injector
sleeve (12) from the head. 25346
6. Remove any copper residue from inside the head 118

using tool 292243 (4, fig. 120).
7. Fit seals (6, fig. 120), onto the new injector
sleeve and fit the sleeve into its bore, making sure
that the sleeve butts up against the bottom of the
seating in the cylinder head, and dress with
dressing tool 293861 (5).
8. Fit guide bush 293746 (9), in the new sleeve (12,
fig. 120), securing it in position by turning the ring
nut (8) clockwise. Insert reamer 293747 (7) in
guide bush (9) and then ream the lower part of the
sleeve.
9. Remove the reamer (7, fig. 120) and unscrew the
ring nut (8) by approx. 10 mm.
10. Press by hand on the ring nut (8, fig. 120) or tap
gently with a rubber mallet, to release the inside
of the guide bush (9) 293746.
11. Remove the guide bush, and fit the milling cutter
293790 (10, fig. 120) in the bush. Install the bush
in the sleeve (12) and fix in position by turning the
ring nut (8) clockwise.
12. Work with the cutter (10, fig. 120) to remove ma- 1
terial until the seating is perfectly smooth and free
from all marks.
13. Once completed, remove the cutter, fit the injec-
tor in the sleeve (12, fig. 120) and check that
stand--out is as specified on page 18.
Cylinder head bolts (2, fig. 3)

If the bolts are to be re--used, check that diameter d 25343

than 11.5 mm; if not, use new bolts. 119
1 2 3 4 5 6 7 8 9 10
12 11
25348
120
Disassembly, removal of residue, installation and reaming of injector sleeve in cylinder head using tool kit 293270
1. Injector sleeve extractor 293784. 7. Reamer 293747.

2. Injector sleeve extractor 293784. 8. Guide bush 293746.
3. M 8 x 1.25 injector retaining nuts. 9. Guide bush 293746.
4. Waste removal tool 292243. 10. Cutter 293790.
5. Injector sleeve dressing tool 293861. 11. Injector sleeve extractor 293784.
6. O--ring seals. 12. Injector sleeve.
Op. 10 102 70
CRANKSHAFT FRONT OIL SEAL
Removal -- Installation
DANGER
equipment.
load to be lifted. 1
Proceed as follows:
1. Carry out operation 90 100 22: Bonnet opening,
only removal (see sect. 90).
2. Carry out operation 90 100 80: Safety guard, only
removal (see sect. 90).
3. Carry out operation 10 406 10: Radiator, only re-
moval (see sect. 90).
25690
4. Loosen the retaining bolts and remove the fan (1)
recovering the spacer. 121
5. Loosen the alternator locknuts (3), and recover
the pulley (1) and belt (2). 1 2
25691
122
6. Loosen the pulley hub locknut (2), remove the
bolts (1) and extract the pulley (2). 1 2
25693
123
7. Extract the crankshaft pulley hub (2), using tool
291504 (1) recovering the woodruff key. 1 2
25694
124
8. Remove the seal (1) from the seat.
1
25695
125
9. To install the front oil seal, proceed as follows.
WARNING 1
-- Respect the tightening torques prescribed on

page 20.
-- Install the oil seal using tool (50138, see page 22
and a striker (1).
-- Fit the hub, locknut and pulley.
-- Assemble the pulley and the fan drive belt.
25696
-- Fit the fan and spacer.
-- Carry out operation 10 406 10: Radiator, only 126
installation (see sect. 90).
-- Carry out operation 90 100 80: Safety guard, only
-- Carry out operation 90 100 22: Bonnet opening,
only installation (see sect. 90).
Op. 10 106 12
ADJUSTING VALVE/ROCKER ARM CLEAR-
ANCE
WARNING
Proceed as follows:
27180
inlet manifold. 127
3. Carry out operation 10 254 44: Exhaust pipe, only
removal (see page 86).
4. Carry out operation 90 100 84: Bonnet guard,
5. Loosen the retaining bolts and remove the cover
(1).
27752
128
6. Remove the flywheel inspection window cover
(1).
25704
129
7. Adjust the clearance between the valves and the
rocker arms using a feeler gauge (1), wrench (3)
and rocker arm adjustment tool 291883 (2) bear-
ing in mind the following recommendations.
-- Rotate the crankshaft so that the inlet and ex-
haust valves of cylinder No. 1 are balanced (start
of induction stroke). In this position the pointer will
be aligned with the reference mark TDC 1 on the
flywheel.
-- Rotate the crankshaft through 3600, returning the
TDC 1 to the previous position, check that the
clearances between valves and rocker arms cor-
27753
respond with the values specified in the table on
page 17. 130
-- Repeat this operation for the other valve pairs,
bearing in mind that the TDC 2 and TDC 3 refer-
ence marks for pistons 2 and 3 are not present on
the flywheel.
8. Refit the parts that were removed, proceeding as
follows.
WARNING
-- Refit the flywheel inspection window cover.

-- Refit the rocker cover.
-- Carry out operation 90 100 84: Bonnet guard,
-- Carry out operation 10 254 44: Exhaust pipe, only
installation (see page 86).
-- Refit the inlet hose.
Op. 10 216 10
FUEL TANK
WARNING
Proceed as follows.
1. Lock the front wheels using chocks.
2. Using a hoist, slightly raise the rear part of the

tractor, position a support stand under the left--
hand lateral gear casing, then remove the rear left
hand wheel.
3. Unscrew the plug (1) and drain the fuel from the
27792
tank into a suitable container (capacity 65
litres--17.17 gal.). 131
4. Loosen the clamp and detach the fuel intake pipe

(1).
27946
132
5. Disconnect the two unions (1) and the fuel return
line (2) from the fuel gauge.
133
6. Unscrew the clamp (1) and remove the fuel inlet
nozzle (2).
134
7. Position a hydraulic jack under the tank, loosen
the retaining screw and remove the front clamp
(1).
135
8. Loosen the retaining screw and remove the rear
clamp (1), lower the jack and remove the fuel
tank.
9. To refit the fuel tank, proceed as follows.
WARNING
-- Position and secure the tank.

-- Position and secure the fuel inlet nozzle.
-- Connect the fuel return pipe.
-- Connect the fuel gauge connections. 136
-- Connect the fuel intake pipe.
-- Fit the left--hand wheel and remove the support
stand.
-- Fill up with fuel (capacity 65 litres).
Op. 10 218 30
FUEL INJECTORS Removal--Installation
WARNING
Proceed as follows:
27180
inlet manifold. 137
3. Unscrew the return lines connecting union (1) and
the injector fuel supply lines (2).
27181
138
4. Loosen the injector retaining bolts (1).
27182
139
5. Extract the injector (2) using a suitable extracting
tool (1).
6. To install the fuel injector, proceed as follows.
WARNING

page 20.
-- Insert and secure the injector in the seat.
-- Tighten the union on the fuel supply lines and the 27183
return lines.
140
-- Refit the inlet hose.
Op. 10 246 14
BOSCH INJECTION PUMP
Removal--Installation, timing and air
bleeding
WARNING
WARNING
Proceed as follows:
1. Raise the engine hood.
removal of right--hand guard (see sect. 90).
3. Unscrew the retaining bolts and remove the
housing (2) on the injection pump drive gear box.
27754
If the conditioning system compressor is fitted,
detach the compressor support bracket (1). 141
4. Make two reference marks (1) on the two gears
to facilitate the subsequent injection pump instal-
lation and timing operations.
27755
142
5. Detach the throttle lead (1) from the injection
pump lever and the electrical lead from the engine
stop electromagnet.
27756
143
6. Loosen the unions: (1) of the injection pump sup-
ply line, (2) the fuel return line and (3) the pump
supply line.
7. Disconnect the pipe that connects the LDA de-
vice to the inlet manifold (only models TN 70 and
TN 75).
27757
144
8. Make sure that the reference marks (2) are indi-
cated for injection pump timing (1). 2
1
27761
145
9. Unscrew the injection pump retaining bolts (1).
27758
146
10. Unscrew the locknut that holds the injection pump
to the drive gear (1).
27759
147
11. Using tool 295042 (1) detach the injection pump
from the gear and recover the injection pump with
the woodruff key.
12. To install the injection pump, proceed as follows.
WARNING

page 20.
-- Assemble the injection pump complete with key, 27760
making sure that the reference marks (made pre-
viously) for timing operations coincide, then fix in 148
position by means of the bolts.
-- Lock the injection pump drive gear in position, us-
ing the nut.
-- Refit the injection pump drive gear box access
cover.
-- Assemble the LDA device connection pipe to the
inlet manifold (for models TN 70 and TN 75).
-- Connect the fuel supply and return lines to the in-
jection pump.
-- Connect the engine stop electromagnet electrical
lead.
-- Connect the injection pump fuel supply lines.
-- Connect the throttle lead to the injection pump.
-- Lower the engine bonnet.
Timing
If the engine does not run evenly, if the timing marks
(1) are not visible, or doubts arise concerning their ac-
curacy, time the injection pump as follows:
25709
149
13. Unscrew the unions of the fuel supply lines (1),
detaching them from the injection pump.
If necessary, disconnect the injection pump sup-
ply lines (2 and 3) and, for models TN 70 and
TN 75, the connection pipe between the LDA de-
vice and the inlet manifold.
27757
150
14. Remove the flywheel inspection window cover
(1).
15. Rotate the crankshaft to bring cylinder No. 1 to
TDC of the compression stroke.
25704
151
16. Remove the injection pump gear cover.
17. Check that the “4” timing marks on gears (1) and
(2) are aligned.
25710
152
18. Check through the inspection window that the
pointer is aligned with the “9” reference marks for
models TN 55 and TN 65 or the “6” marks for
models TN 70 and TN 75.
26107
153
19. With the injection pump in position but with the
mounting bolts loose, remove the plug (1) on the
pump housing.
20. Fit dial gauge 291754 (1) fig. 147 and relative tool 1
291755 (2), pre--loading the shaft by approxi-
mately 2.5 mm (0.0984 in.).
21. Turn the flywheel slowly backwards, so as to
bring the plunger to BDC at the start of the deliv-
ery stroke (the point at which the dial gauge
needle stops falling).
25711
154
22. Zero--set the dial gauge and slowly turn the fly-
wheel clockwise (as viewed from the fan end of
the engine), until the pointer lines up with the “9”
reference marks for models TN 55 and TN 65 or
the “6” marks for models TN 70 and TN 75.
23. Check on the dial gauge that the plunger has
completed a stroke of 1 mm (0.0394 in.) up to this
point, if not, slacken off the pump mounting bolts.
24. Turn the pump counter--clockwise if the plunger
has completed a stroke of less than 1 mm (0.0394
1 2
in.), and clockwise if the stroke is greater than 1
mm (0.0394 in.), repeating the test until the cor-
rect stroke is obtained. 25712
25. Having obtained the correct plunger stroke, fix 155
the pump in position by tightening the mounting
nuts to the torque specified on page 20.
26. Stamp pump timing marks (1, as shown in figure
201) on the pump mounting flange, distance
piece and housing.
27. Remove the dial gauge 291754 (1) and relative
tool 291755 (2) and replace the plug and tighten
to a torque of 8 to 10 Nm (6 to 7 ft-lbs).
28. Refit other parts in the reverse of the dismantling
order.
Fuel circuit air bleeding
29. Unscrew the bleeder plug (1) by approx. 2 turns.
30. Operate the priming lever (1, fig. 150) until the
fuel coming out of the hole in the plug is free of air
bubbles.
31. Tighten the plug (1).
27508
156
32. Loosen the fuel supply lines unions on the three
injectors.
27561
157
33. Operate the priming lever (1) again, until the fuel
coming out of the injectors is free of air bubbles,
then tighten the injector unions.
34. Start the engine and check that it runs evenly.
27509
158
Op. 10 254 44
EXHAUST PIPE
Removal--Installation.
WARNING
Proceed as follows.
27645
1. Remove the two retaining bolts (2), and the ex- 159
haust pipe bracket (1).
2. Remove the retaining bolt (2), washer and ex-
haust pipe (1).
3. To refit the exhaust pipe, proceed as follows.
WARNING
Always use suitable tools to align holes in parts.
-- Fit the exhaust pipe, washer and retaining bolt.

27646
-- Fit the exhaust pipe bracket and the two retaining
bolts. 160
Op. 10 402 11
COOLANT PUMP -- Removal--Installation
with the radiator removed.
DANGER
Lift and handle all heavy parts using suitable lifting 1
equipment.
load to be lifted.
Proceed as follows:
25690
3. Carry out operation 10 406 10: Radiator, only re- 161
moval (see sect. 90).
4. Loosen the retaining bolts and remove the fan (1)
recovering the spacer.
5. Loosen the alternator locknuts (3), and recover
the pulley (1) and belt (2). 1 2
25691
162
pump lines (1), remove the bolts and the pump. 1
7. To install the coolant pump, proceed as follows.
WARNING

page 20.
-- Fit the coolant pump and connect the lower lines
to the pump. 25692
-- Assemble the pulley and the fan drive belt. 163

-- Fit the fan and spacer. installation (see sect. 90).
-- Carry out operation 10 406 10: Radiator, only -- Carry out operation 90 100 22: Bonnet opening,
installation (see sect 90). only installation (see sect. 90).
Op. 10 402 28
COOLANT PUMP -- Overhaul 1 2
3
WARNING 4
5
6
Note -- The bearing (9, fig. 156) forms a single piece 10 9 8 7
with the control shaft (10); it is a sealed unit and re- 14262
quires no lubrication during running.
164
Overhaul the pump as follows:
-- Remove the cover (4, fig. 156) and the screw (2)
retaining the shaft(10) and bearing (9).
-- Gently tap the end of the shaft (10, fig. 156) on the
rotor side (5) to break the film of oxide between
the shaft and the rotor; fit extractor 291182 (1) 1
and remove the rotor.
-- Remove the front seal bushing (7, fig. 156).
-- Use a punch to extract the shaft (10), complete
with bearing (9) and fan hub (1), from the pump
housing (6, fig. 156).
5976
165
Note -- Only remove the seal (8, fig. 156) when it

needs to be replaced. 1
Check components for wear, replacing parts that are

in poor condition.
Refit the parts, proceeding as follows:
-- Fit the shaft (10, fig. 156) complete with bearing
(9) and hub (1) on the pump housing (6) and se- 21662
cure with the retaining screw (2), after having

spread a film of LOCTITE 242. 166
-- In the event of replacement, fit the seal (8) into the
seat, using tool 293280 (1, fig. 158).
-- Heat the rotor (1) in an air oven, to reach a tempera- 1
ture difference of 130 to 150 °C (266 to 302 °F) in
relation to the shaft (2).
-- Place the rotor (1) on the shaft (2), easing it onto
the end so as not to damage the bearing, until ob-
taining an operating clearance of G = 0.5 to 0.7
mm (0.0197 to 0.0276 in.) (see fig. 156).
-- Fit the seal (3, fig. 156) and the cover (4) securing
in position with the relevant screws.
2
21663
167
Op. 10 402 30
COOLING SYSTEM THERMOSTAT
Removal--Installation
WARNING
Proceed as follows:
only removal (see sect. 90). 27180
2. Loosen the band clamps (1, 2 and 3) and remove 168

the inlet hose.
removal of the left--hand guard (see sect. 90).
4. Unscrew the plug (1), drain off a few litres of cool-
ant and then tighten the plug.
27749
169
bracket (1).
27750
170
6. Loosen the band clamp (2) and remove the hose
(1).
27751
171
7. Loosen the retaining bolts and detach the hous-
ing--seat (1) of the thermostat valve. 1
25699
172
8. Extract the thermostat valve (1) from the seat.
9. To refit the thermostat valve, proceed as follows. 1
WARNING

page 20.
-- Position the thermostat valve in the seat.
-- Assemble the valve housing--seat.
-- Connect and secure the hose to the housing seat. 25700
-- Fit and secure the bracket to the radiator. 173

-- Fit and secure the inlet manifold.
-- Make sure that the drainage plug is tightened,
then fill up the engine cooling system with coolant
(see page 6, section 00 for prescribed products
and quantities).
installation of the left--hand guard (see sect. 90).
Op. 10 406 10
RADIATOR
DANGER
equipment.
load to be lifted.
Proceed as follows:
only removal (see sect. 90). 27749
2. Carry out operation 90 100 80: Safety guard, only 174

3. Unscrew the plug (1), drain off the coolant, then
tighten the plug.
4. Unscrew the retaining bolts and extract the POW-

ER SHUTTLE heat exchanger (1), if fitted, and
remove the relevant support bracket, if neces-
sary.
27762
175
5. Loosen the retaining bolts (1 and 2) that connect
the power steering piping to the radiator.
27763
176
6. Remove the clogged air filter sensor connection
(1).
27764
177
7. Disconnect the horn connection (1).
27765
178
8. Unscrew the clamp (1) and remove the oil vapour
recovery hose (2).
27766
179
9. Unscrew the clamp and disconnect the inlet hose
(1).
10. Unscrew the band clamp and remove the pipe (3)
that connects the radiator to the expansion tank.
11. Unscrew the retaining clamp and disconnect the
upper (4) and lower hoses.
12. Unscrew the radiator retaining bracket (2).
27767
180
13. Unscrew the retaining bolts and remove the ra-
diator (1), complete with air filter (2) and inlet
hose.
14. Unscrew the retaining bolts and detach the air fil-
ter from the radiator.
15. To refit the radiator, proceed as follows.
WARNING
-- Respect the tightening torques prescribed on 27768

page 20.
181
-- Position the radiator and secure with the relevant
bolts.
-- Fit the air filter and inlet hose.
-- Connect and secure the upper and lower hoses
and the expansion tank -- radiator connecting
pipe.
-- Fit the tank retaining bracket.
-- Fit the inlet hose and vapour recovery hose.
-- Connect the air filter and horn connectors.
-- Fit the power steering piping to the radiator.
-- Assemble the POWER SHUTTLE heat exchang-
er.
-- Tighten the coolant drainage plug and fill up the
system (for quantities and products, see 00, page
6).
SECTION 18 -- CLUTCH -- CHAPTER 1 1
SECTION 18 -- CLUTCH
Chapter 1 -- Clutch
CONTENTS

18 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
18 110 10 Clutch -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
18 110 30 11”/11” Dual disk clutch -- Test bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
18 110 30 11” Single disk clutch (Version with Power--Shuttle) -- Test bench overhaul . . . . . . . . . . . 15
18 100 40 Clutch adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LUK 11”/11” CLUTCH -- GENERAL SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . single disk, dry plate dual clutch unit

Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical: pedal operated main
clutch; hand lever operated PTO
clutch
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . single Belleville spring disk
Driven plate lining material for main clutch: . . . . . . . . . . . . . . . . . .
-- premodification models and models TN 55 and TN 65 postmodi- organic agglomerate
fication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- models TN 70 and TN 75 (from frame no. 1127769) . . . . . . cerametallic
Driven plate lining material for PTO clutch . . . . . . . . . . . . . . . . . . cerametallic

Driven plate thickness:
-- main clutch (9, fig. 1):
premodification models and models TN 55 and TN 65 post- mm 9.7 to 10.3
modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (in.) (0.3818 to 0.4055)
models TN 70 and TN 75 (from frame no. 1127769) . . . . . . ” 9.6 to 10.4
(0.3779 to 0.4094)
-- PTO clutch (11, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” 7.3 to 7.9
(0.2874 to 0.3110)
-- wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” see pages 21 and 22
Clearance between main clutch release sleeve and housing . . . mm 0.050 to 0.151
(in.) (0.0019 to 0.0059)
Clearance between PTO clutch release sleeve and housing . . . mm 0.060 to 0.136
(in.) (0.0023 to 0053)
Release lever height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . see pages 22 and 23
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 24
2 SECTION 18 -- CLUTCH -- CHAPTER 1
LUK 11” CLUTCH -- GENERAL SPECIFICATIONS”
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . single dry plate clutch
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical: pedal operated

Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . Belleville spring disk
Driven plate lining material for PTO clutch . . . . . . . . . . . . . . . . . . . cerametallic pads

Driven plate thickness for PTO clutch (1, fig. 2) mm 7.3 to 7.9
(in) (0.2874 to 0.3110)
-- Driven plate wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” see page 21

Clearance between clutch release sliding sleeve and support . . . mm 0.050 to 0.151
(in) (0.0019 to 0.0059)
TIGHTENING TORQUES
Tightening torque
PARTS TO TIGHTEN Thread
Nm ft lbs
11”/11” clutch/flywheel retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 20 to 25 15 to 18
Release command fork securing bolt (7, fig. 1) . . . . . . . . . . . . . . . M 16 x 1.5 136 to 165 100 to 122
Clutch casing/engine retaining nuts (3, fig. 1) . . . . . . . . . . . . . . . . M 12 x 1.25 117 to 129 86 to 95
Nut for sleeve cover fixing stud (6, fig. 1) . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 20 to 25 15 to 18
TOOLS

can only be carried out with ESSENTIAL tools indi-
cated by an (X).
sults, it is also necessary to use the recommended
specific tools listed below and certain other tools,
cluded in this manual.
List of specific tools required for the various

operations described in this section.
X 294073 Pin for centering and adjustment of
11”/11” clutches.
X 295023 Clutch adjustment gauge (with
294073).
293763 Set of wrenches for adjustment of
levers in 11”/11” LUK clutches.
Longitudinal section of 11”/11” LUK clutch

1. PTO
clutch release lever adjuster.
2. Belleville spring disk.
2
D1
3. Bolts or nuts securing clutch casing to the engine.
4. PTO clutch release levers. 1 D 3 4 5
5. Release sleeves for main
and PTO clutch, complete with thrust bearings.
6. Nuts for sleeve cover fixing
studs.
7. Fork lever retaining bolts.
8. Main clutch release lever.
9. Main clutch disk.
10. Main clutch release lever adjuster.
11. PTO clutch disk.
12. Bearing on flywheel.
a Clutch (up to frame no. 1127768).
b Clutch (from frame no. 1127769).
D = 97.5 mm (3.8386 in.). Nominal distance of release
levers (8) from clutch contact surface on flywheel.
D1 = 139.5 mm (5.4921 in.). Nominal distance of release
NOTE:During assembly apply sealing compound on

surfaces marked with an X as shown in Section 21,
X
Chapter 1, page 30.
12 11 10 9 8 7 6 a
25961
1
Longitudinal section of 11” LUK clutch”
1. Main clutch disk.
1 2 3
2. PTO clutch release levers.
3. Release sleeves, complete with D1
thrust bearing.
4. Nuts for sleeve cover
studs.
5. Fork lever retaining bolt.
6. Screws and bolts securing the clutch casing to the
engine.
a Clutch (up to frame no. 1127768).
b Clutch (from frame no. 1127769).
D1 = 139.5 mm (5.4921 in.). Nominal distance of release
NOTE:When refitting the clutch, check that the clutch

disks are positioned as in the drawing.
NOTE:During assembly apply sealing compound on X

surfaces marked with an X as shown in Section 21,
Chapter 1, page 30.
6 5 4
25962 a
2
CLUTCH TROUBLESHOOTING
Clutch slips 1. Disks 11 and 9, fig. 1, disk 1, Check and compare the data given on
fig. 2 pressure plates and fly- the pages indicated, replace any
wheel worn. parts which are worn up to or over the
limit and adjust levers and clutch con-
trol linkage.
2. Belleville spring disk (2, fig. 1) Replace the Belleville spring disk.
distorted or damaged.
3. Oil or grease contaminating Replace the disks, identify and elimi-
the friction lining of disks (11 nate the source of the lubricant inside
and 9, fig. 1) and disk (1, the clutch housing and thoroughly
fig. 2) clean the friction surfaces.
Clutch jerks 1. Partial seizure of the external Check rod pivots and lubricate.
control linkage.
2. Clutch disk (9, page 1) de- Replace the disk and adjust the clutch
formed. control lever.
3. Clutch disk (9, fig. 3) with dam- Replace the disk.
aged hub springs or loose hub
rivets.
4. Oil or grease contaminating Replace the disks, identify and elimi-
the friction lining of disks (11 nate the source of the lubricant inside
and 9, fig. 1) and disk (1, the clutch housing and thoroughly
fig. 2) clean the friction surfaces.
Clutch sticks and drags 1. Clutch disks (11 and 9, fig. 1) Replace and adjust the disks.
and disk (1, fig. 2) deformed.
2. Seizure of external control Check, replace faulty parts and lubri-
linkage. cate.
3. Controls incorrectly adjusted. Adjust the controls (see page 19).
Clutch noisy when engaged 1. Thrust bearing worn. Replace bearing

and/or disengaged
2. Clutch disk (9, fig. 1) with hub Replace the disk.
springs damaged.
Clutch pedal too stiff 1. Partial seizure of the external Check rod pivots and lubricate.
control linkage.
2. Partial seizure of pedal pivot. Check pivot and lubricate.
Op. 18 110 10
CLUTCH Removal--Installation
DANGER
equipment.
lifted.
WARNING
Proceed as follows:

only removal (see section 90).
2. Remove the front ballast (3), if fitted, using a hoist 27786

and two steel cables (1), extract the pin (2) and
remove the ballast. 3
3. Unscrew the plug and drain the oil from the rear
transmission casing (the prescribed quantity is 42
litres; 11.095 gallons).
25628
4
4. Disconnect the engine oil pressure sensor con-
nection (1).
5
5. Unscrew the speedometer/tachometer (2) con-

trol cable and relative retaining clamp (1).
6. Unscrew the screw that holds the exhaust pipe to
the left--hand steps.
6
7. Remove the two flexible hoses (1) on the power
steering control.
7
8. Loosen the relative retaining clamps and remove
the thermostarter and fuel pump pipes (1 and 2).
8
9. Unscrew the brake oil reservoir (2) retaining
screws, remove the reservoir and attach to the
right--hand handrail (1).
9
10. Disconnect the electric motor connectors (1).
10
11. Disconnect the thermostarter connection (1).
11
12. Disconnect the power steering oil delivery pipes
(1).
12
13. Disconnect the filter pipe (1), loosen the relative
clamp and detach the pipe (2).
13
14. Remove the accelerator control cable (1) from the

control lever.
15. Carry out operation 23 101 26: Transmission
shafts and guard, only removal (see section 23).
14
16. Position a fixed stand under the front part of the
clutch box, connect a hoist with a chain to the rear
hook on the engine and tighten the chain.
17. Wedge the front axle assembly to prevent the en-
gine from oscillating, then unscrew the bolts that
hold the clutch housing to the engine.
15
18. Using the front wheels, separate the clutch hous-
ing from the engine.
16
19. Using tool 294073 (1), unscrew the retaining bolts
and remove the clutch (2).
20. To refit the engine to the clutch box, proceed as

follows.
WARNING
27785
-- Apply the torque settings listed on page 2. 17

-- Before refitting the engine to the clutch box care- -- Attach the brake oil reservoir to the inlet manifold.
fully clean the mating surfaces and apply sealing
compound (2 mm diameter), according to the dia- -- Connect and secure the thermostarter and fuel
gram shown Section 21, Chapter 1, page 33. pump piping.
-- Refit the clutch to the flywheel, using tool 294073. -- Connect the power steering control pipes.
-- Using a hoist, position the engine--front axle as- -- Attach the exhaust pipe to the left--hand steps.
sembly and secure in position.
-- Connect and secure the speedometer/tachome-
-- Carry out operation 23 101 26: Transmission
ter control cable.
shafts and guard, only installation (see section
23). -- Connect the engine oil pressure sensor connec-
-- Connect the accelerator control cable to the con- tor.
trol lever.
-- Position and secure the ballasting.
-- Connect the lift delivery and return lines to the
transmission oil filter. -- Carry out operation 90 100 22: Bonnet opening,
only installation (see section 90).
-- Connect the power steering oil delivery pipes.
-- Tighten the plug on the rear gear transmission
-- Connect the thermostarter and engine electrical housing and fill up with oil (see page 6, section 00
connections. for prescribed products and quantities).
Op. 18 110 30
11”/11” DUAL CLUTCH 1
Test bench overhaul
WARNING
Proceed as follows:
24791
1. Unscrew the three PTO clutch lever adjustment
nuts (1). 18
2. Take off the pressure plate (1) with the three coil
springs (2) and the three washers. 1
24792
19
3. Position three clamps (1) at intervals of 120o on
the clutch body and gradually and carefully
squeeze the Belleville spring disk.
1
24793
20
4. Extract the six spring retaining pins (1) from their
seats. 1
24794
21
5. Remove the three clamps and extract the Belle-

ville spring disk (1). 1
24975
22
6. Loosen the three locknuts (1) of the main clutch
lever adjustment screws.
1
24976
23
7. Remove the three the main clutch lever adjust-
ment screws (1).
1
24977
24
8. Extract the main clutch pressure plate (1).
1
24978
25
9. Extract the main clutch disk (1).

1
24979
26
10. Remove the springs (1) of the PTO clutch control
levers.
1
24980
27
11. Extract the pivot pins (1) of the PTO clutch control
levers. 1
24981
28
12. Remove the springs (1) of the main clutch control
levers. 1
24982
29
13. Extract the pivot pins (1) of the main clutch control
levers. 1
14. To refit the clutch, proceed as follows.
WARNING
-- Refit the lever pivot pins and the relative springs.

-- Refit the main clutch disk in the housing.
-- Install the main clutch pressure plate , securing to
the pins with the bolts. 24983
-- Install the Belleville spring disk, carefully position 30

the three clamps and evenly and progressively
compress the spring. Insert the six pins, making
sure that they are securely inserted in their re-
spective seats, then remove the clamps.
-- Install the PTO clutch disk; fit the three washers
and the coil springs on the pins and secure with
the three nuts.
Op. 18 110 30
11” SINGLE CLUTCH (Fitted with the Pow-
er-Shuttle gearbox) Test bench overhaul
WARNING
Proceed as follows:
1. Unscrew the three clutch lever adjustment nuts
(1).
25963
31
2. Remove the pressure plate (1) with the coil
springs (2) on the levers.
25964
32
3. Unscrew the six retaining bolts (1) of the Power
Shuttle gear control disk and remove (2).
4. To refit the clutch, proceed as follows.
WARNING
-- Refit the Power Shuttle gear control disk in the

clutch housing. 25965
-- Install the pressure plates and secure to the 33

spring coils.
-- Tighten the lever adjustment nuts.

CHECKS, MEASUREMENTS AND REPAIRS

-- DUAL CLUTCH
WARNING
Minimum permissible dimensions after re--facing of

parts subject to wear in the 11”/11” dual clutch
A ≥ 15.5 mm (0.6102 in.); B ≥ 22.7 mm (0.8937 in.);
D ≥ 15.8 mm (0.6220 in.).
1. Flywheel. 25966
2. PTO clutch pressure plate. 34

3. Main clutch pressure plate.
4. Clutch cover.
Minimum permissible dimensions after re--facing of

parts subject to wear in the 11” single clutch
A ≥ 15.5 mm (0.6102 in.); C ≥ 15.8 mm (0.6220 in.).
1. Flywheel.
2. PTO clutch pressure plate.
3. Clutch cover.
-- Check the degree of wear on the PTO disks (11,

fig. 1 and 1, fig. 2) and gear (9), replacing them
if the linings have worn down (or are nearly worn
down) to the rivet heads.
-- Replace the disk when the oil has soaked into the
organic agglomerate surfaces. 25967
Minimum permissible dimensions after re--fac- 35

ing of parts subject to wear in the 11”/11” dual
clutch and 11” single clutch.
-- Check the friction surface conditions of the pres-
sure plates and the clutch cover.
Generally, by means of turning, up to 1 mm of ma-
terial can be removed from the cast iron friction
surfaces of the clutch cover (3), the pressure
plate ring (2) and the flywheel (see Section 10,
Chap. 1, page 56).
When parts (1), (2), (3) and (4 figs. 34 and 35), are
to be repaired by removing material, proceed as fol-
lows:
-- If it is necessary to reface the friction surfaces on

the PTO clutch pressure plate (2, fig. 34 and 35),
remember that the amount removed in relation to
the nominal thickness (A), must also be removed
from the base of the flywheel housing (4, fig. 34
and 35) in order to regain the original position of
the pressure plate (2) in relation to the flywheel.
The position indicated by (C) of the clutch cover

(4, see fig. 34 and 35) must be calculated using
the following formula:
C = 71.4 + A
Where:
A = Thickness of the pressure plate after refacing.
C = Height of the clutch cover after refacing.
-- When the friction surfaces of the main clutch

pressure plate ring (3, fig. 34) or the clutch cover
(4), need refacing, remember that the removal of
material cannot be compensated by turning the
clutch cover (4) on the flywheel side.
-- Therefore the least possible material should be

removed from parts (3 and 4), for longer clutch
life.
NOTE:If, after having refaced parts (3 and 4, fig. 34),

several times, the main clutch disk starts to slip, the
entire clutch assembly must be replaced.
-- Refit the clutch assembly as shown on page 6).
RELEASE LEVER HEIGHT ADJUSTMENT

OF 11”/11” DUAL CLUTCH RELEASE
1. After overhauling the clutch, fit centering pin

25968
294073 (1) and fit the entire clutch assembly to
the flywheel, then tighten the bolts (2). 36
2. Fit gauge 295023 (1) on the centering pin and,

using a feeler gauge, adjust the clutch release
levers (2) to obtain a clearance of 0.1 mm (0.0039
in.).
25969
37
3. Rotate the gauge 295023 (1) and, using a feeler
gauge, adjust the PTO clutch release levers (2)
to obtain a clearance of 0.1 mm (0.0039 in.).
25970
38
COPLANARITY OF 11” SINGLE PLATE
CLUTCH RELEASE LEVERS”
4. After overhauling the clutch, fit centering pin
294073 (1), gauge 295023 (2), and fit the entire
clutch assembly to the flywheel, then tighten the
bolts (3).
25971
39
5. Using a feeler gauge, adjust the coplanarity of the
clutch release lever to obtain a clearance of 0.1
mm (0.0039 in.).
25972
40
Op. 18 100 40
CLUTCH ADJUSTMENTS
WARNING
1. If the clutch pedal (1) position becomes uncom-

fortable or when the clutch is overhauled, check
that height (A), from the centre of the main gear
clutch pedal in relation to the platform, is 140 ± 2
mm (5.5118 ± 0.0787 in). If not, adjust as follows: 41
-- Loosen the locknut (2) and turn the nut (1)

counter--clockwise.
-- Check that the height of the pedal is 140 ± 2 mm

(5.5118 ± 0.0787 in.).
-- Tighten the locknut (2).
-- Operate the unit four or five times.
-- Check that the height of the clutch pedal (1, fig. 41)
is as prescribed.
-- If necessary, reset to the correct value (A, fig. 41)

as previously described. 42
PTO CLUTCH CONTROL ADJUSTMENTS
WARNING
1. With the PTO lever (1) disengaged, using the ex-

ternal lever (4, fig. 44) (located on the clutch cas-
ing), move the internal lever into contact with the
PTO clutch engagement sleeve. 43
2. Loosen the locknut (2), extract the pin (5), tighten

the fork (1) on the control cable (3) until the cable
is slightly tensioned, whilst making sure that the
external lever (4) has not moved.
3. Carry out 5 engage/disengage manoeuvers and

check that the conditions (in the points previously
mentioned) have not changed.
4. Unscrew the fork (1) by half a turn (180o).
5. Tighten the locknut (2). 44

6. With the lever (1) disengaged, check that it is in
contact with the relative stop (2).
45
7. Check that the clearance (L) between the lever
(1) and the relative sector (2) is 3 to 5 mm (.118
to .196 ins).
If not, unscrew the sector (2) retaining bolts and
position correctly.
46
SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 1
SECTION 21 -- TRANSMISSIONS
Chapter 1 -- Mechanical Transmission (8 x 8),

(16 + 16) Synchro-Command, and 8 x 8 Non-Synchronized Transmissions
CONTENTS
21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 118 10 Rear Transmission/Gearbox, Removal--Installation
21 118 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 118 85 Rear Transmission/Gearbox, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear Transmission/Gearbox, driving and driven shafts clearance adjustments . . . . . . . . 31
21 130 10 Gearbox Control Lever, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

21 130 11 Range Gear Control Lever, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SHUTTLE UNIT MAIN DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical type with spur

gearing, located between the
main clutch and the gearbox.
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hand lever located on left--hand

side of operator
GEARBOX AND RANGE GEAR MAIN DATA
Gearbox (8 x 8 non-synchronized) BSN: 1279632 . . . . . . . . . . . . 4-speed constant mesh,

non-synchronized gears
with non-synchronized
F/R shuttle shift.
ASN: 1279632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-speed constant mesh,

non-synchronized gears with
synchronized F/R shuttle shift.
2 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

(continued)
Gearbox (Synchro-Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed constant mesh,

synchronized on all gears with
synchronized F/R shuttle shift.
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical
Range gear (16 x 16 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ordinary gear train with 4 ranges
for a total of 16 gears.
Range gear (8 x 8 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ordinary gear train with 2 ranges
-- Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears
Gearbox and range gear operating system . . . . . . . . . . . . . . . . . . independent, by means of lever
located on right--hand side of
operator
Thickness of gearbox driving shaft adjustment ring
(4, figs. 7 and 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.5 -- 0.75 -- 1.0 -- 1.25 -- 1.5 --
1.75 -- 2.0 -- 2.25
(in.) (0.0197 -- 0.0295 -- 0.0393 --
0.0492 -- 0.0591 -- 0.0689 --
0.0787 -- 0.0886)
Thickness of gearbox driven shaft adjustment ring
(12, figs. 7 and 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.5 -- 0.75 -- 1.0 -- 1.25 -- 1.5 --
1.75 -- 2.0 -- 2.25
(in.) (0.0197 -- 0.0295 -- 0.0393 --
0.0492 -- 0.0591 -- 0.0689 --
0.0787 -- 0.0886)
Springs for detent balls on gearbox and range gear control rods:
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 42
(in.) (1.6535)
-- length of springs under load of 75.5 to 83.3 N (7.7 to 8.5 kg;
16.98 to 18.74 lb.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35
(in.) (1.3780)
Springs (1, page 10) for gearbox and range gear control levers:
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44
(in.) (1.7323)
-- length of springs under load of 31.4 to 35.3 N (3.2 to 3.6 kg;
7.05 to 7.94 lb.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35
(in.) (1.3780)
TORQUE SETTINGS
Tightening torque
PART Thread
Nm ft. lbs.
Sleeve cover retaining nuts (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 20 to 25 14 to 18
Gearbox driving and driven shafts bearing cover screws (C2) . . . M 10 x 1.25 84 to 93 62 to 69
Retaining bolts securing creeper clutch casing to rear transmis-
sion/gearbox (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 117 to 129 86 to 95
Driven gear shaft locknut (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 32 x 1.5 280 to 309 206 to 228
Drive gear housing cover retaining screws (C5) . . . . . . . . . . . . . . . -- 43 to 51 32 to 38
Pressure switches (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 51 to 72 38 to 53
Parking brake inspection cover, gearbox and range control relay
levers support cover retaining screws (C7) . . . . . . . . . . . . . . . . . . . M 10 x 1.25 43 to 51 32 to 38
Bolts or nuts securing creeper clutch casing to the engine (C8) . M 12 x 1.25 117 to 129 86 to 95
TORQUE SETTINGS
C1 -- 20 to 25 Nm C3 -- 117 to 129 Nm C4 -- 280 to 309 Nm C5 -- 43 to 51 Nm

(14 to 18 ft. lbs.) (86 to 95 ft. lbs.) (206 to 228 ft. lbs.) (32 to 38 ft. lbs.)
25612 C2 -- 84 to 93 Nm
(62 to 69 ft. lbs.)
C6 -- 51 to 72 Nm
(38 to 53 ft. lbs.)
25614 C8 -- 117 to 129 Nm C7 -- 43 to 51 Nm

(86 to 95 ft. lbs.) 27928
(32 to 38 ft. lbs.)
1
SPECIAL TOOLS 290090 Rotating stand for overhaul opera-

tions.
X 294074 Tool for gearbox driving and driven
shafts adjustment.
X 294087 Driving shaft rod for lifting unit.
cated by an (X). X 294075 Driven shaft retaining tool.
To work safely and efficiently and obtain the best re- X 294076 Pliers for gearbox shafts circlips.
sults, it is also necessary to use the recommended X 294090 Driving shaft fitting guides.
special tools listed below and certain other tools
X 294091 Driven shaft fitting guides.
cluded in this manual. X 294099 Adjuster handle (with 294100 and
294145).
X 294100 Power take--off drive shaft seal splin-
List of special tools required for the various opera- ing tool (with 294099).
tions described in this section. X 294145 Power take--off drive shaft roller bear-
291517 Clutch casing lift hook. ings splining tool (with 294099).
24663
2
Tool to be made for disassembly--assembly of the final drives, to be used with 50114.
(Stamp No. 50091 on the tool -- Measurement in mm [ins])
1. Make 2 tie--rods in C 40 bon material. -- Make in Aq 42 D material.

(1.57)
(11.81)
(9.84)
(7.87)
(1.96)
(1.57)
(3.54)
(.787) (.787)
26258
Tool to be made for lateral gear removal--installation, use with a part of 50091.
(Mark tool No. 50114 -- Measurement in mm [ins])
Make in Fe 42 C material -- (*) Measurement according to hoist seat.

4
Bracket to be made for gearbox overhaul on rotating stand
1. Rotating stand axis.
Make in Fe 42C material.
5
Bracket to be made for gearbox overhaul on rotating stand
Make in Fe 42C material.
150 (5.905)
20 15
(.787) (.590)
M12x1.25
7 (.275)
25618
Guide pin for re--fitting the gearbox in the casing

(Mark part with no. 50158 -- Measurement in mm [ins])
Make in C 40 material.
1 2 3 4 5 6 7 8
X
X
25619 13 12 11 10 9
7
Longitudinal cross--sectional view of gearbox and gear range (16 + 16 Synchro-Command)
1. Seal. 8. Bevel pinion shaft.

2. Power take--off shaft support roller bearings. 9. Selector sleeve for low or medium--high speeds.
3. Shuttle control synchroniser. 10. Synchroniser for 1st and 2nd speed.
4. Gearbox driving gear clearance adjusting thickness. 11. Synchroniser for 3rd and 4th speed.
5. Power take--off shaft. 12. Gearbox driven shaft gear clearance adjusting thick-
6. Gearbox driving gear. ness.
7. Selector sleeve for high or medium--low speeds. 13. Gearbox driven shaft.
NOTE: When fitting apply sealing compound to surfaces X as shown on 33.

8
Longitudinal cross--sectional view of gearbox and gear range (8 x 8 Synchro-Command)
1. Low speed intermediate gears. 2. Selector sleeve for high speeds.

50032165
9
Longitudinal cross--sectional view of gearbox and gear range
(8 x 8 Non-Synchronized with Synchronized Mechanical Shuttle)
1. Low speed intermediate gears. 2. Selector sleeve for high speeds.

3 4
2
50032166
10
Longitudinal cross--sectional view of gearbox and gear range (8 x 8 Non-Synchronized)
1. Low speed intermediate gears. 3. Selector sleeve for low speeds.

2. Selector sleeve for high speeds. 4. Bevel pinion.
11
Cross--sectional view of gearbox and range gear
1. Shuttle control external rod. 4. Gear selector internal rod.

2. Gear control external rod spring. 5. Shuttle selector internal rod.
3. Gear control external rod.

1 2 3
8
5
25621
25622
25623
12
Cross--sectional view of gearbox and range gear
1. Range gear control external rod spring. 5. Shuttle relay gear (reverse gear)
2. Range gear control external rod. 6. Detent ball and spring.
3. Shuttle control fork. 7. Lubricating oil external pipes.
4. Shuttle selector synchroniser. 8. Lubricating oil internal pipes.

DESCRIPTION AND OPERATION
Gearbox and shuttle (Synchro-Command) Gearbox and shuttle (Non-Synchronized)
4--speed gearbox with constant--mesh helical gears 4-speed gearbox with constant-mesh helical gears
controlled by two synchronisers. controlled by two non-synchronized selection
sleeves.
The range gear has cascade--type constant--mesh
spur gears. The range gears provide 2 gears -- 8 x 8 version.
The range gear provides: 2 gears (8 x 8 version) or The gearbox and range gears are controlled by two
4 gears (16 + 16 version). independent levers located on the right hand side of
The gearbox and the range gears are controlled by the operator.
two independent levers located on the right--hand The shuttle is a mechanical device providing 8 for-
side of the operator. ward and 8 reverse gears (8 x 8). It is controlled by a
The shuttle is a mechanical device, providing: 8 for- lever located on the left hand side of the operator.
ward gears and 8 reverse gears (8 x 8 version) or 16
forward gears and 16 reverse gears (16 + 16 version). The shuttle is composed of three spur gears and
It is controlled by a lever located on the cab platform shuttle driving gear, shuttle driven gear, and inter-
to the left of the operator. mediate gear. Engagement is by means of non-syn-
chronized selection sleave. After SN 1279632 en-
The shuttle is composed of a group of three spur gagement is by means of a synchronizer located in
gears: shuttle driving gear, shuttle driven gear and in- the gear unit.
termediate gear, engagement is by means of a syn-
chroniser located in the gear unit. The shuttle is installed inside the clutch casing, be-
tween the clutch and the gearbox.
The shuttle is installed inside the clutch casing be-
tween the clutch and the gearbox. Lubrication is by Lubrication is by means of the oil in the rear transmis-
means of the oil in the rear transmission. sion/gearbox.
GEARBOX, GEAR RANGE AND SHUTTLE TROUBLESHOOTING
Spontaneous disengagement of 1. Levers and relay rods incor- Adjust correctly.

gearbox. rectly adjusted.
2. Control levers retaining Replace springs.

springs damaged.
3. Synchroniser teeth or selec- Remove the transmission--gearbox

tion sleeves damaged. casing and replace the synchronisers
or the sleeves.
4. Incomplete engagement Eliminate the cause and reset the

stroke. complete stroke.
GEARBOX, GEAR RANGE AND SHUTTLE TROUBLESHOOTING
(continued)
Difficulty in engaging the gearbox. 1. Levers and relay rods incor- Adjust correctly.
rectly adjusted.
2. Stiffness and/or partial seizu- Check rod pivots and lubricate.

re of external levers and relay
rods.
3. Main clutch dragging. See Section 18.
4. Synchronisers or selection Remove the transmission--gearbox

sleeves damaged. casing and replace the synchronisers
or the sleeves.
5. Internal controls do not slide Overhaul the controls.

easily: rods, forks and slee-
ves.
Excessive noise in gearbox or 1. Worn or damaged internal Remove the transmission--gearbox

shuttle. parts. casing and replace the damaged
parts.
Op. 21 118 10 -- 21 118 12

REAR TRANSMISSION--GEARBOX
DANGER
equipment.
Make sure that the units or parts are supported by
lifted.
Proceed as follows:
1. Carry out operation 90 110 50: Control panel, only

removal (see Section 90, Chapter 1).
2. Carry out operation 90 114 26: Rear roll bar, only

3. Carry out operation 90 116 24: Rear guard, only


shafts and guard, only removal (see Section 23,
Chapter 1).
5. Carry out operation 10 216 10: Fuel tank, only re-

moval (see Section 10, Chapter 1).
7. Remove the top link of the third point.
8. Using a hoist and sling (1) raise the rear part of the
tractor, position a fixed support stand under the 27837
towing hook, then remove the right--hand (2) and
left hand wheels. 13
9. Unscrew the plug and drain the oil from the rear
litres; 11.10 gallons).
25628
14
10. Unscrew the stabiliser strut bracket retaining
bolts (1).
27840
15
11. Attach tool 50091 (1) and adapter 50114 (2) to the
lateral gear unit body.
27841
16
12. Position a hydraulic jack (2) under the gear unit,
unscrew the retaining bolts and, using the jack
(2), remove the right--hand gear unit (1) and the
spacer.
13. Detach and remove the vertical rods, complete
with the lower arms.
27842
17
14. Remove the pick--up bar, connect the pick--up
hitch hook (2), using a chain (1), to the hoist, loos-
1 2
en the retaining bolts and detach the hook.
25627
18
15. Disconnect and remove the lift auxiliary control

valve control pipes (1) and trailer brake control 1 2
(2).
25449
19
16. Unscrew the retaining bolts and extract the Lift--
O--Matic control lever (1).
1
25450
20
17. Unscrew the retaining bolts on the lift (1) and re-
cover the trailer brake control pipes support
bracket.
Disconnect the power take--off speed sensor
connections, if necessary.
1
25451
21
18. Attach the lifting hook 291517 (1) to the lift (2)
and, by means of the hoist, raise and remove the
1 2
lift.
25452
22
19. Unscrew and remove the filter pipes (2) and the
transmission--gearbox casing pipes.
20. Disconnect the union (3) on the front differential
lock control pipes and loosen the clamp.
27795
23
21. Unscrew the clamp (1) and detach the sleeve on
the oil intake pipes, unscrew the union (2) and re-
move the lift oil feed pipes, detach and remove
the two transmission gearbox casing pipes.
27796
24
22. Disconnect the brake control pipes (1) from the
brake block and the rear transmission casing and
remove.
23. Unscrew the union and the retaining bolt, then re-
move the pipes (2).
25
24. Disconnect the unions on the heat exchanger
pipes (1).
1
25640
26
25. Disconnect the unions (2) and remove the pipes

(1 and 3). 1 2 3
26. Unscrew the retaining bolts and remove the cab
support bracket (on both sides).
25642
27
27. Position a fixed stand (1) under the engine.
1
27943
28
28. Screw on the four hooks (1) and, using a chain,
connect them to a hoist, unscrew the retaining 1
bolts that secure the clutch casing to the engine
and detach the engine, together with the rear
transmission.
27944
29
29. Position the rear transmission--clutch unit on a
workbench. Unscrew the retaining bolts and re-
1
cover the services control valve (1).
25654
30
30. Extract the pin (3), detach the external lever (1),
unscrew the retaining bolts and remove the sup- 1 2
port (2), complete with control lever.
3
25655
31
31. Remove: the parking brake control lever (5), the
drive gear control oil union (4) and the electric 3
1 2
sensors (1, 2 and 3).
5
25656
32
32. Position two nylon slings (1) under the clutch cas-
ing (2) and attach to the hoist. Unscrew the retain- 1 2
ing bolts that secure the clutch casing to the
transmission casing and remove.
33. To refit the rear transmission--gearbox case, pro-
ceed as follows.
WARNING
-- For the correct orientation of the various parts, re-

fer to the illustrations on pages 8, 9, 10, 11, 12, 13 25657
and 14. 33
-- Before refitting boxes, supports and covers, thor-
oughly clean and degrease the mating surfaces
and apply a strip of sealing compound of about 2
mm (0.0787 inches) diameter as shown in the
diagram on page 33.
page 2.
-- Re--fit the clutch casing on the rear transmission--
gearbox case.
-- Fit the electric sensors, the drive gear oil union
and the parking brake control external lever.
-- Fit the support complete with creeper--shuttle

control lever, remembering to attach the lever (2)
to the bracket (1) and to insert the unit positioned
1
in a counter--clockwise direction, then straight-
en--up the unit when it comes into contact with the 2
casing to facilitate the insertion of the lever (2) in
the relative teeth.
-- Assemble the creeper--shuttle external control le-
ver.
-- Fit the services control valve.
-- Refit the rear transmission--gearbox case and
clutch casing to the engine. 27945
-- Attach the cab mounting.
-- Connect all of the services control valve pipes.
-- Connect the brake and services control pipes. 34
-- Connect the heat exchanger pipes.
-- Fit the rear transmission--gearbox case oil intake
pipes.
-- Connect the trailer brake and lift control pipes.
-- Connect all of the lateral filter and front differential
lock control pipes.
-- Tighten the rear transmission--gearbox oil drain-
age plug.
-- Assemble the hydraulic lift.
-- Fit the Lift--O--Matic control lever.
-- Assemble and connect the auxiliary control valve
support and trailer brake valve pipes.
-- Fit the hitch--hook and pick--up bar.
-- Re--connect the vertical rods to the lift arms.
-- Fit the brake disks, the differential axle shafts and
side gears.
-- Fit the rear wheels and remove the support
stands.
-- Carry out operation 10 216 10: Fuel tank, only
installation (see Section 10, Chapter 1).
shafts and guard, only installation (see Section
23, Chapter 1).
-- Carry out operation 90 116 24: Rear guard, only
-- Carry out operation 90 114 26: Rear roll bar, only
-- Carry out operation 90 110 50: Control panel, only
-- Fill up the rear transmission--gearbox casing (see
page 6, section 00 for prescribed products and
quantities).
Op. 21 118 85
REAR GEARBOX TRANSMISSION
Disassembly-- Assembly
WARNING
Proceed as follows.
1. Fix the gearbox --transmission casing to the rotat-

ing stand 290090 using brackets 50157 (see
Figs. 4 and 5).
2. Carry out operation 23 101 40 or 23 202 50 Drive

gear casing assembly, only removal (see Section
23, Chapter 1).
3. Unscrew the retaining bolts and remove the cover

(1) with the gearbox lever and gear unit.
4. Detach the power take--off control shaft following 25717
the instructions in section 31. 35
5. Remove the parking brake casing cover and ex-

tract the circlip (1) that secures the parking brake
control lever.
25718
36
6. Extract the parking brake control lever(2) and re-
cover the sleeve--cam (1).
25721
37
7. Loosen the retaining bolt and remove the cover

(1).
25734
38
8. Remove the circlip (2) and recover the unit (1)
composed of the brake disk and the relative fric-
tion sectors.
25735
39
9. Fit tool 294087 (1) on the driving shaft and lock in
position, insert tool 294075 (2) on the gearbox
driven shaft and tighten.
NOTE: If the gearbox in question is a standard fitting,

fit a M 12 x 1.25 x 40 screw together with a ∅ 12 x ∅
45 (0.4724 x 1.7717 in.) washer and 3 mm (0.1181 in.)
shim, instead of tool 294075 (2).
25736
40
10. Remove the circlip from the front side of the cas-
ing and, using an extracting tool, extract the final
drive driven shaft and recover the driven gears
(1).
25737
41
11. Extract the lubrication pipe (1) from the gearbox.
25738
42
12. Remove the circlip (1) and the union (2), com-
plete with the lubrication pressure adjustment
valve.
25739
43
13. Unscrew the lubrication union (1) from the left--
hand side of the casing.
25740
44
14. Remove the union (2) and the lubrication sleeve
(1).
25741
45
15. Enlarge the circlip (1) that secures the gearbox

driving shaft.
25742
46
16. From the drive gear case, enlarge the circlip (1)
that secures the gearbox driven shaft.
25744
47
17. Unscrew the gearbox retaining bolts (1) and re-
move, using a hoist.
25743
48
18. Fit tool 294074 (2) in a vice and remove the mo-
bile part (1) of the tool.
25774
49
19. Fit the gearbox unit to the tool 294074 (1) and re--
fit the mobile part (2) of the tool.
25775
50
20. Remove the pins (1) to free the gearbox control
forks (on one side).
25776
51
21. Extract the pins (1) on the other side of the gear-
box and remove: the upper part (1) of tool
294074, tool 294087 (2) from the driving shaft
and the retaining tool 294075 from the driven
shaft.
25777
52
22. Remove the driving (1) and driven (2) shafts.
25778
53
23. From the opposite side, remove the rod stop ring
(2), extract and recover the shuttle control fork
(1).
25779
54
24. Extract the circlip (1) and recover the synchronis-
er (2).
25780
55
25. Unscrew the retaining bolt (2) and recover the pin
(3), relay gear (1) and relative bearings and thrust
washers.
25781
56
26. Enlarge the circlip (3) that secures the driven gear
(1) to the gearbox support (2) and remove the
gear (1).
25782
57
27. Enlarge the circlip (1) and extract the gearbox
driven shaft (2).
28. To re--fit the transmission--gearbox casing, pro-

ceed as follows.
WARNING
Always use appropriate tools to align fixing holes. 25783
58
fer to the illustrations on pages 8, 9, 10, 11, 12, 13
and 14.
-- Before refitting boxes, supports and covers, thor-

oughly clean and degrease the mating surfaces
and apply a strip of sealing compound of about 2
mm (0.0787 in.) diameter as shown in the dia-
gram on page 33.

page 2.
-- Carry out the gearbox driven and driving shaft ad-

justments noted on page 32.
-- Fit the gearbox driving shaft on the relative sup-

port.
-- Fit the gearbox driven gear on the relative sup-

port.
-- Fit the reverse drive gear complete with thrust

washer, bearing and retaining bolt.
-- Assemble the synchroniser and circlip.
-- Fit the shuttle control rod, fork and stop circlip.
-- Assemble the driven and driving shafts, the con-

trol forks and lock in position by means of tools
294075 and 294087, fit the mobile part of tool
294074.
-- Fit the control forks to the rods using the pins.
-- Detach the mobile part of the tool 294074 and re-

move the gearbox unit from the tool.
-- Fit tools 294090 and 294091 (1) on the driving 25784

shaft lock circlip and the driven shaft lock circlip
(respectively). 59
-- Using a hoist, fit the gearbox unit in the casing

and recover the tools 294090 (1) and 294091 (the
latter must be recovered from the drive gear cas-
ing). Secure in position with the bolts.
-- Fit the lubrication union and sleeve.
-- Fit the lubrication pressure adjustment valve,
complete with the union and circlip.
-- Assemble the lubrication pipes.
-- Fit the driven shaft and gears.
-- Remove tools 294087 and 294075 from the driv- 25785
ing and driven shafts.
60
-- Fit the parking brake unit, comprising brake disks
and friction sectors.
-- Fit the cover (1) and secure with the bolt (2).
NOTE: Apply Loctite 242 thread locker to the thread

on bolt (2) and tighten to a torque setting of 19.6 Nm
(15 ft. lbs.).
-- Assemble the parking brake control lever, com-

plete with cam sleeve and circlip.
-- Fit the parking brake cover.
-- Assemble the power take--off control shaft, fol-
lowing the instructions in Section 31.
-- Fit the cover with the gearbox control lever and 25786
final drive.
61
-- Carry out operation 23 101 40 or 23 202 50 Drive
gear casing assembly, only installation (see Sec-
tion 23, Chapter 1).
-- Detach the transmission--gearbox casing from
the rotating stand.
TRANSMISSION--GEARBOX CASING
Gearbox driving and driven shafts clearance
adjustment.
WARNING
Proceed as follows.
NOTE: When fitted, the driving and driven shaft gears

must provide an axial clearance of 0.8 mm (0.0314 in.)
in order to guarantee correct synchronizer operation.
25787
29. Using tool 294074 (1) clamped in the vice, attach 62

the gearbox support complete with the driving
and driven shafts without the respective adjust-
ment shims (4 and 12, page 8), fit the mobile part
(2) on the tool.
30. Using a depth gauge, measure the distance (L)
between the top of the tool 294074 (1) and the cir-
clip (3) on the driving shaft bearing.
31. Measure the distance (L1) between the top of the
tool 294074 (1) and the circlip (2) on the driven
shaft bearing.
32. The adjustment shim (4, page 8) to fit on the driv-
ing shaft is given by:
S = L -- 46.5 -- 1.0 mm (1.830 -- .039 ins)
where
L = measurement read
46.5 mm (1.830 ins) = theoretical measurement
of tool 294074
1.0 mm (.039 ins) = synchronizer operating
clearance.
Round down the value.
33. The adjustment shim (12, page 8) to fit on the
driven shaft is given by:
S1 = L1 -- 36 -- 1.0 mm (1.417 -- .039 ins) 25788
L1 = measurement read
36 mm (1.417 ins) = theoretical measurement of 63
tool 294074
1.0 mm (.039 ins) = synchronizer operating
clearance.
Round down the value
Example:
L = 48.8 mm (1.921 ins). measurement read
L1 = 37.8 mm (1.488 ins). measurement read
46.5 mm (1.830 ins) = theoretical measurement
of tool 294074
36 mm (1.417 ins) = theoretical measurement of
tool 294074
1.0 mm (.039 ins) = synchronizers operating
clearance.
S = 48.8 -- 46.5 -- 1.0 = 1.3 mm (S = 1.921 -- 1.830
-- .039 = .052 ins) (adjustment shim 4, page 6).
S1 = 37.8 -- 36 -- 1.0 = 0.8 mm (S = 1.488 -- 1.417
-- .039 = .032 ins)(adjustment shim 12, page 6).
The adjustment shims are listed on page 2.
Round down the value.
27152
64
Sealing compound application diagram for transmission--gear box casing
The types of sealing compounds to be applied are specified on page 1, section 00.
Op. 21 130 10
GEARBOX CONTROL LEVER
WARNING
Proceed as follows.
1. Unscrew the four retaining bolts and the guard
retaining flange.
2. Raise the guard (2), remove the gearbox control
lever retaining bolt and the gearbox control lever
(1).
NOTE: If a POWER SHUTTLE gearbox is fitted,

disconnect the electrical contact located on the gear
lever.
3. To refit the gearbox control lever, proceed as

follows.
65
WARNING

lever.
-- Fit the gearbox control lever (1, Figure 65),

complete with guard (2) on the control sleeve.
-- Fit the lever retaining bolt to the control sleeve,
lower the guard, fit the four guard retaining flange
retaining bolts.
Op. 21 130 11
RANGE GEAR CONTROL LEVER
WARNING
Proceed as follows.
1. Unscrew the four retaining bolts and the guard
retaining flange.
2. Raise the guard (2), remove the range control
lever retaining bolt and the range control lever (1).
3. To refit the range control lever, proceed as
follows.
WARNING
66
lever.
-- Fit the range control lever (1, Figure 66),

complete with guard (2) on the control sleeve.
-- Fit the lever retaining bolt to the control sleeve,
lower the guard, fit the four guard retaining flange
retaining bolts.
SECTION 21 -- TRANSMISSIONS
Chapter 2 -- Power Shuttle Transmission (8 + 8 and 16 + 16 versions)
CONTENTS

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
21 118 85 Transmission--Gearbox, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 134 46 Power shuttle control valve, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
21 134 70 A + B Clutch valve solenoids, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
21 134 70 Dump valve solenoid, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
21 154 34
21 154 60 Clutch casing, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Description of systems (ECM and CDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Automatic self-diagnosis (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ECM First start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diagnosis during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Calibration and diagnostic unit (CDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power shuttle fault code priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fault codes indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Calibration and diagnostics unit use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
HH menu access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
H1 -- Clutches A and B calibration error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
H2 -- Clutches A and B calibration values display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
H3 -- System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
H4 -- Power shuttle hardware and software revision levels . . . . . . . . . . . . . . . . . . . . . . . . . 48
H5 -- Control switch diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
H6 -- Clutch A fill time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
H7 -- Clutch B fill time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
H8 -- Erasure of data stored in NVM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
H9 -- Voltmeter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
HA -- Clutch pedal potentiometer and status switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Clutch pedal potentiometer replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
HC -- Transmission oil temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
HD -- Hi/Lo Synchronizer operation (not used in standard) . . . . . . . . . . . . . . . . . . . . . . . . . 67
HE -- Gear change adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
HF -- Stored error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Troubleshooting fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Power Shuttle (8 x 8 and 16 x 16) electronic control unit input/output wiring diagram . 276
SHUTTLE MAIN DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical type with spur
gearing, located between the
main clutch and the gearbox.
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hand lever located on left-hand

side of the steering wheel

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed constant mesh,
synchronised on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical
Range gear (16 + 16 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ordinary gear train with 4 ranges

Range gear (8 + 8 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ordinary gear train with 2 ranges

-- Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears
Gearbox and range gear operating system . . . . . . . . . . . . . . . . . . . independent, by means of lever

located on right--hand side of
operator
For missing data see Chapter 1, page 2.

POWER SHUTTLE MAIN DATA
Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . . no. 6
Thickness of driven plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.00 to 2.08
(in.) (0.0787 to 0.0819)
Driven plates material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sintered
Number of driving plates in each clutch . . . . . . . . . . . . . . . . . . . . . . no. 6
Thickness of driving plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.00 -- 2.20
(in.) (0.0787 -- 0.0866)
Driving plates material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel
Thickness of clutch assembly under a load of 1600 N
(163.1 kg; 359.57 lb.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.9 to 25.1 (1)
(in.) (0.9803 to 0.9882)
Clutch piston return spring (4, pages 7 and 8):
-- number of springs for each clutch . . . . . . . . . . . . . . . . . . . . . . . no. 7
-- spring free height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.30
(in.) (0.1299)
-- spring height under a load of 1255 N (128 kg; 282.19 lb.) . . . mm 2.62
(in.) (0.1031)
Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mounted on the outer left--hand
side of the
transmission--rear--gearbox
casing, comprising 3 control
solenoid valves
Power Shuttle and services transmission working pressure . . . . . bar 15.7
(psi) (227.7)
By--pass valve spring (6, page 11):
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35.5
(in.) (1.3976)
-- spring length under load of 37.2 to 41.2 N
(3.8 to 4.2 kg; 8.4 to 9.2 lb.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 25.5
(in.) (1.0039)
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fixed to the pump housing on
suction side
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the same as used for the
hydrostatic steering system (see
Section 41, Chapter 2)
(1) Value to obtain by varying the thickness of the driving plates.
TORQUE VALUES
Tightening torque
PART Thread
Nm ft. lbs.
For missing data see Chapter 1, page 2.
Solenoid valve retaining nut (C1) (•) . . . . . . . . . . . . . . . . . . . . . . . . -- 1.7 to 2.8 1.2 to 2
Solenoid valve spool retaining bolt (C2) . . . . . . . . . . . . . . . . . . . . . -- 14.9 to 20.3 10 to 15
Solenoid valve spool retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . -- 47 to 54 35 to 40
Solenoid valve retaining nut (C4) (•) . . . . . . . . . . . . . . . . . . . . . . . . -- 5.4 to 8.1 4 to 6
(•) Apply 1 or 2 drops of LOCTITE 542 before tightening
(10 to 15 ft. lbs.)

C1 --14.9 to 20.3 Nm
C2 --1.7 to 2.8 Nm (1.2 to 2 ft. lbs.)
C3 --47 to 54 Nm (35 to 40 ft. lbs.)
27951A (4 to 6 ft. lbs.)

C4 --5.4 to 8.1 Nm
C3 --47 to 54 Nm
C4 --5.4 to 8.1 Nm
(35 to 40 ft. lbs.)
(4 to 6 ft. lbs.)
25792
1
SPECIAL TOOLS X 294086 Driving shaft rod for lifting unit.
X 294075 Driven shaft retaining tool.
can only be carried out with SPECIAL tools indicated X 294099 Adjuster handle (with 294100 and
by an (X). 294145).
To work safely and efficiently and obtain the best re- X 294100 Power take--off drive shaft seal splin-
sults, it is also necessary to use the recommended ing tool (with 294099).
specific tools listed below and certain other tools
which are to be made according to the drawings in- X 294145 Power take--off drive shaft roller bear-
cluded in this manual. ings splining tool (with 294099).
X 294076 Pliers for gearbox shafts circlips.
List of specific tools required for the various opera- X 294090 Driving shaft assembly guide.
tions described in this section.
X 294091 Driven shaft fitting guides.
291517 Clutch casing lift hook.
X 294077 Adapter (with 295021).
290090 Rotating stand for overhaul opera-
tions. X 295021 Tool for hydraulic clutch piston springs
(with 294077).
X 294074 Tool for gearbox driving and driven
shafts adjustment. X 292870 Hydraulic pressure testing kit.
24663
(Stamp No. 50091 on the tool -- Measurement in mm [ins])
1. Make 2 tie--rods in C 40 bon material. -- Make in Aq 42 D material.

(1.57)
(11.81)
(9.84)
(7.87)
(1.96)
(1.57)
(3.54)
(.787) (.787)
26258

4
Bracket to be made for gearbox overhaul on rotating stand.
(Mark part with no. 50157 -- Measurement in mm [ins]).
Make in Aq 42 material.
Bracket to be made for gearbox overhaul on rotating stand.

1. Rotating stand axis -- Make in Aq 42 material.
150 (5.905)
20 15
(.787) (.590)
M12x1.25
7 (.275)
25618
6
Guide pin for re--fitting the gearbox in the casing.
Make in C 40 material.
7
Longitudinal cross--sectional view of Power Shuttle gearbox (16 + 16 version)
1. Forward gear control clutch piston. 7. Reverse drive shaft.

2. Forward gear control clutch. 8. Reverse driven shaft.
3. Piston return Belleville washer.
9. Reverse gear clutch control piping.
4. Reverse gear control clutch.
5. Reverse gear control clutch piston. 10. Forward gear clutch control piping.
6. Forward gear drive shaft. 11. Lubrication control pipes.
NOTE: For missing data see Chapter 1.

7 6 5
Cross--sectional views of Power Shuttle gearbox
1. Power Shuttle control valve. 6. Reverse return gear.

2. Gear control internal rod. 7. Roller bearing.
3. Gear control external lever. 8. Dump solenoid valve.
4. Pin. 9. Operating pressure testing plugs.
5. Pin retaining bolt (4).
Longitudinal cross--sectional view of Power Shuttle gearbox (8 + 8 version)
1. Low gear intermediate gears. 3. Selector sleeve for low gears.

2. Selector sleeve for high gears. 4. Bevel pinion.
NOTE: For missing data see Chapter 1.

5
4
MDE0067A
10
Power Shuttle control valve.
1. Reverse clutch control solenoid valve. 4. Reverse gears clutch working pressure control plug.
2. Forward clutch control solenoid valve. 5. Forward gears clutch working pressure control plug.
3. Dump solenoid valve.
CLUTCHES CONTROL PRESSURE TEST
Unscrew plug (4) or (5) on the clutch to be tested and If the pressure is incorrect adjust the shims (3, fig. 11),
connect a pressure gauge from kit 292870 to the rela- increase if the pressure is low and decrease if too
tive hole. high.
Start the engine and check the pressure (see page 2).
1 2 3
27804A
6 5
11
Cross--sectional view of services control valve
1. Four wheel drive release solenoid valve. 4. By--pass valve spring.

2. Spring for services control oil pressure adjustment 5. By--pass valve.
valve. 6. Services control pressure adjustment valve.
3. Services control oil pressure adjustment shims.
Gears
4--speed gearbox with constant--mesh helical gears
controlled by two synchronizers.
The range gear has cascade--type constant--mesh
spur gears.
The range gear provides 2 gear ranges (8 + 8 version)
or 4 gear ranges (16 + 16 version).
The gearbox and the range gears are controlled by
two independent levers located on the right--hand
side of the operator.
Gear reversal is obtained by means of the lever (1)

located on the left--hand side of the steering wheel. It
is not necessary to press the clutch pedal, but the en-
gine rpm and tractor speed must be reduced.
Lubrication is by means of the oil in the rear trans-
mission/gearbox.
Power Shuttle unit
The Power Shuttle gearbox is controlled by two multi--

disk clutches in an oil bath.
This provides hydraulic control of 4 gears for each
range, both forward and in reverse.
12
Gear and range selection is performed by pressing
the clutch pedal and operating the control levers lo-
cated on the right--hand side of the operator.
The front clutch controls the forward gears, the rear
clutch controls the reverse gears.
GEARBOX AND GEAR RANGE TROUBLESHOOTING
See Chapter 1, pages 15 and 16.

Op. 21 118 85
TRANSMISSION--GEARBOX
Disassembly--Assembly
WARNING
Proceed as follows:
1. Carry out operation 21 118 10: Rear transmis-
sion--gearbox casing, only removal (see Chapter
1).
2. Unscrew the retaining bolts and recover the ser-
vices control valve (1).
1
25654
13
3. Unscrew the retaining bolts and detach the Pow-
er Shuttle (1) control valve.
4. Attach the transmission--gearbox casing on the
rotating stand 290090 using brackets 50160 (see
pages 5 and 6).
27087
14
5. Unscrew the retaining bolts (1) on the clutch con-
trol pipes (2).
27088
15
6. Remove the clutch control pipes (1) by means of
rotation.
27089
16
7. Unscrew the unions (1 and 2) on the clutch con-
trol pipes and recover the internal unions.
27090
17
8. Loosen the shuttle control pin (1).
9. Complete the gearbox removal operations by fol-
lowing the instructions in Chapter 1, page 24.
10. To refit the unit, carry out the disassembly opera-

tions in reverse order, following the instructions in
Chapter 1.
27091
18
Op. 21 134 46
POWER SHUTTLE CONTROL VALVE
WARNING
Handle all parts with extreme care. Do not put your
hands or fingers between parts. Wear suitable safety
clothing -- safety goggles, gloves and shoes.
With the Power Shuttle control valve on the work-

bench, proceed as follows.
1. Extract the pin (1) that retains the creeper unit 27109
control lever (2). 19
2. Extract the creeper unit control lever (1) and re-

cover the internal lever (2).
27110
20
3. Unscrew the nut (1) and extract the solenoid
valve (2).
27111
21
4. Unscrew the solenoid valve pin (1).
5. Repeat operations 3 and 4 with solenoid valve
(2).
27112
22
6. Unscrew the nut (2) and extract the solenoid
valve (1).
27113
23
8. Repeat operations 6 and 7 with solenoid valves
(2 and 3).
27114
24
9. Remove the circlip (1).
27115
25
10. Remove the plug (1) and recover the shuttle con-
trol pin (2).
27116
26
11. Remove the switch (1).
12. To refit the Power Shuttle control valve, proceed
as follows.
WARNING

fer to the illustrations on page 10.
-- Respect the tightening torque values prescribed
on page 3. 27117
-- Fit the switch. 27

-- Assemble the control pin, plug and circlip.
-- Fit the pins and relative solenoid valves then, af-
ter having applied 1 or 2 drops of Loctite 542,
tighten the nuts.
-- Assemble the internal lever, the creeper unit con-
trol lever and the pin.
Op. 21 134 70
A + B CLUTCH VALVE SOLENOIDS
WARNING
In order to remove a control solenoid valve from the

two clutches, the working area must be kept clean.
Proceed as follows.
1. Carry out operation 10 216 10 Fuel tank, only re-

2. Disconnect the solenoid valve connection (1). 28
3. Loosen the nut and remove the solenoid valve

(1).
29
5. To refit the control valve solenoid, proceed as fol-

lows.
WARNING
-- Screw the pin on the solenoid valve.
-- Fit and secure the solenoid valve.

30
-- Connect the electrical connection.
-- Carry out operation 10 216 10 Fuel tank, only

Op. 21 134 70
DUMP VALVE SOLENOID
WARNING
In order to remove a control solenoid valve from the

gearbox, the working area must be kept clean. Pro-
ceed as follows.
1. Carry out operation 10 216 10 Fuel tank, only re-

2. Disconnect the solenoid valve connection (1) and

unscrew the retaining nut. 31
3. Remove the solenoid valve (1).
32
5. To refit the control valve solenoid, proceed as fol-

lows.
WARNING
-- Screw the pin on the solenoid valve.
-- Fit and secure the solenoid valve.

33
-- Connect the electrical connection.
-- Carry out operation 10 216 10 Fuel tank, only

Op. 21 154 34 -- 21 154 60
CLUTCH CASING
WARNING
Proceed as follows.
1. Carry out operation 21 118 12 : Rear transmis-

sion--gearbox casing, only removal (see Chapter
1).
2. Attach the clutch casing to the rotating stand
290090 using brackets 50157 (see figs.NO TAG
and NO TAG).
27092
clutch control pipes (1). 34
4. Unscrew the retaining bolt and recover the sleeve

(1), fork (2) lever (3) and spring (4).
27093
35
5. Unscrew the rear bearing support retaining bolts
(1).
27094
36
6. Unscrew the front bearing support retaining bolts
(1).
27095
37
7. Insert tool 294086 (1) on the clutch unit (2), se-
cure in position and remove, using a hoist.
27096
38
8. Position the clutch unit (1) on a workbench, re-
move tool 294086 (2) and separate the unit into
two parts.
27097
39
sleeve (1) for the power take--off clutch engage-
ment sleeve.
27098
40
10. Remove the circlip (1) and remove the front bear-
ing support (2).
27100
41
11. Remove the circlip (1) and remove the shaft (2).
27101
42
12. Remove the circlip (1) that secures the clutch disk
assembly.
27102
43
13. Extract the gear (1) and recover the clutch disk
assembly (2) and the relative springs (3).
27103
44
14. Using an extractor (1) and tool 295021 (2) com-
press the Belleville washer (3), remove the sto
ring (4) and recover the washer and piston.
27104
45
15. Remove the sto ring (1) and extract the clutch
body (2).
27105
46
16. Remove the front bearing support (1).
271106
47
17. Remove the circlip (1) and remove the bearing
(2).
18. To refit the clutch casing, proceed as follows.
WARNING
-- For the correct orientation of the various parts,

see cross-sectional views earlier in this chapter. 27107

earlier in this chapter. 48
-- Assemble the front bearing and circlip on the -- Unite the two clutch units and lock in position by
shaft. means of tool 294086.
-- Fit the front bearing support. -- Insert the clutch unit in the casing.
-- Insert the clutch body and stop ring.

-- Fit the front bearing support by means of the
bolts.
-- Insert the piston and fit the Belleville washer and
circlip.
-- Fit the rear bearing support by means of the bolts.
-- Assemble the clutch disk assembly complete
with springs and gear. -- Assemble the lever, spring, fork and the power
take--off clutch engagement sleeve.
-- Assemble the other clutch, as described previ-
ously.
-- fit the clutch control pipes.
-- Fit the shaft and stop ring.
-- Detach the casing from the rotating stand.
-- Assemble the front bearing support and circlip.
-- Carry out operation 21 118 12: Rear trans-
-- Fit the sleeve for the power take--off clutch en- mission--gearbox casing, only installation (see
gagement sleeve. Chapter 1).
DESCRIPTION OF SYSTEMS
(ECM and CDU)
The TN standard series tractor has various
electro-hydraulic components for controlling the
Power Shuttle transmission. This transmission has
an Electronic Control Module (ECM) for
commanding, operating, and troubleshooting certain B
A
input and output sensors. Because of this, an
operating software program is required to monitor
and control the system. A diagnostic software
program is used to indicate when and where a system
fault occurs. The software program is in a tool called C
the Calibhration/Diagnostic Unit (CDU, tool
#CNH294084). 49
The CDU has three operating buttons. The “H Menu”
button (A) is used to scroll through different menus
and for initial access to the calibration and diagnostic
systems. The “up arrow” (B) and “down arrow” (C) are
used to scroll through list in each menu, start
calibrations, and saving/erasing.
The ECM has two modes of “Auto Self-Diagnostic”
functions to detect abnormal operating conditions in
the ECM itself or in the ECM controls or monitors. The
ECM will detect failures or abnormal conditions and
once detected will switch to error logic and failure
management logic circuitry in the ECM. The first
mode is when the key switch (1) is turned from the
“OFF” (A) position to the “RUN” position (B) when
starting the tractor. This self-diagnosis could continue
up to 30 seconds if abnormal conditions are detected.
The second mode is real-time self-diagnosis while
the tractor is running, “RUN” posistion (B).
50
If the ECM detects a system error or abnormal
condition in either mode, the ECM error logic will 1
signal an error code, causing the alarm lamp (1) on
the instrument panel to flash a code. The failure
management logic will signal error codes according
to their priority.
51
AUTOMATIC SELF-DIAGNOSIS (ECM)
The ECM automatically does a self-diagnosis of the
different system parts when the key switch (1) is
turned from the “OFF” position to the “ON” position
(B). The configuration of these parts is already stored
in the non-volatile memory.
During the self-diagnosis period the trasmission
status light will remain on. The self-diagnosis process
could continue for up to 30 seconds if abnormal
conditions are detected.
NOTE: If an attempt is made to move the tractor prior

to the completion of self diagnosis the self diagnosis will 52
be terminated, the transmission status light will be
turned off and error codes may not be displayed.
Once the self-diagnosis is completed and if there is

an abnormal condition or failure in one or more of the
ECM controlled systems, the ECM will cause the
alarm lamp on the instrument panel to flash a code,
or the transmission status light will begin flashing
alerting the operator that there is a problem.
The ECM also performs real-time self diagnosis of
system components while the tractor is running,
“RUN” position (B). The ECM will perform this at
regular intervals to check for possible system failures
or abnormal conditions.
If the ECM detects a system error or abnormal
condition while the tractor is running, the ECM error
logic will signal an error code, causing the alarm lamp
on the instrument panel to flash a code, alerting the
operator that there is a problem. The failure
management logic will signal error codes according
to their priority.
If an error with lower priority occurs while an error of
higher priority is already being signaled, the lower
priority error will be stored until the error of higher
priority has been removed.
If an error of higher priority occurs while an error of
lower priority is being signaled, the higher priority
error will be displayed after the lower priority error
sequence has been displayed.
ECM -- FIRST START--UP
(Self Configuration)
The ECM will require configuration when any one of

the following circumstances has occurred.
-- At the end of the production line.
-- Following ECM replacement.
-- Following erasure of the Non--Volatile memory

(NVM) (see H8 MENU).
-- Following manual configuration (see H3 MENU). 53
Turn switch (1) to B (ON) without switching on the en-

gine.
Indicator (1) (fig. 54) will be illuminated (non--flash-
ing), after a while the indicator will flash to repeat the
recognised configuration code -- i.e.: rapid flashing,
followed by 1 flash.
-- Turn the key (1, fig. 53) to OFF for a few seconds:
the configuration is now saved in the Non--Volatile
memory (NVM).
MDD3231A
54
DIAGNOSIS DURING OPERATION 2 -- Priority Numerical value.
Diagnosis during operation is in real time and checks 3 -- Detection Group of conditions creating
for the eventual presence of anomalous conditions at the fault.
regular intervals, whilst the functional software is 4 -- Effects The eventual effect of the fault
working. on the system.
The diagnosis should check all conditions shown 5 -- Correction The condition that corrects
under the DIAGNOSIS MINIMUM CONDITIONS the fault, if possible, and the
headings. functional change of the sys-
tem after this correction.
FAULT DETECTION AND ANOMALOUS 6 -- Not displayed during calibration.
CONDITIONS MANAGEMENT LOGIC 7 -- Not displayed in Cab Test mode: this mode is ac-
The start--up and functional code also includes the cessed by sending a series of ”commands” to the
faults detection and anomalous conditions manage- ECM, through the serial connection.
ment logic.
The TROUBLESHOOTING FAULT CODES head-
This logic processes the faults information provided ing contains the definitions of the system errors,
by the diagnostics (start--up diagnosis and diagnosis subdivided into the aforementioned fields.
during operation) and functional bodies, indicating
the condition of the system, in order to detect ”system
faults” and ”anomalous conditions”.
MULTIPLE ANOMALOUS CONDITIONS --
The faults detection and anomalous conditions man- PRIORITY
agement logic also diagnoses ECM and external cir-
cuit anomalies, where the hardware can not be diag- In the event of multiple anomalous conditions, as ex-
nosed directly; i.e. it checks the coherence of the plained in the following heading, the display logic
functional bodies and their configuration. uses the “Priority” field to establish the code to dis-
Each time the faults logic detects a ”system error” or play. Unless otherwise specified, the resulting mul-
an ”anomalous condition”, the fault code will be dis- tiple anomalous condition effect/condition is provided
played, it creates a fault which is processed by the by superimposing each individual effect/correction; in
faults buffer logic in the non--volatile memory, the the event of incompatibility between the different
faults display logic and the anomalous conditions corrections, the correction linked with the highest
management logic. priority fault is used.
The anomalous conditions management logic con-
siders the effect of the faults that effect tractor oper-
ation. FAULT DISPLAY LOGIC
The logic also manages the correction procedure for
a fault condition. Introduction
Each fault is described using the following fields:
As soon as a problem is detected, it must be dis-
1 -- Fault code Numerical value. played by the indicator lamp (1, fig. 55).
CALIBRATION AND DIAGNOSTICS UNIT 8V SENSORS SUPPLY.
(CDU) a) short to +12.
The Calibration and Diagnostics Unit (CDU) indicates b) short to ground or open circuit.
fault conditions relative to the HH menu, e.g.: calibra- c) nominal range deviation.
tion Uxx codes.
12VF KEY SUPPLY.
Other fault conditions, unless masked by the ”cab
12VD CLUTCH DRIVERS SUPPLY.
tester mode” or ”calibration mode”, are flashed on the
illuminated signal lamp (1, fig. 55). a) short to ground or open circuit.
b) nominal range deviation.
DIAGNOSIS MINIMUM CONDITIONS
INPUT DIAGNOSTICS
ECM and relative circuits fault.
The unit must be provided with a watchdog for ECM Anomalous condition description and reset
anomalous conditions). For each of the following inputs, apart from when
The length of the software cycle should be 10 ms, there is an ECM fault, the following anomalous condi-
whereas the watchdog pause should be 16.5 ms tions must be diagnosed (independently of the ECM
(longer pauses are not recommended). status).
This check must be carried out at least every 10 ms
Reaction to fault. (longer pauses are not recommended).
At start--up, and in the event of microprocessor AN1 Clutch pedal potentiometer.
anomalous conditions, none of the solenoid valves AN2 Forward gear lever switch.
are enabled. AN8 Not used.
AN9 Not used.
Follow--up reaction.
AN10 Not used.
In the event of an anomalous condition, the watchdog
AN11 HI pushbutton.
and reset circuit must guarantee that the ECM does
not excite the solenoid valves. AN12 LO push button.
-- short to 5V or 12V.
POWER SUPPLY DIAGNOSTICS -- short to ground or circuit open.
For each ulterior current supply, apart from when AN3 Reverse gear lever switch.
there is an ECM fault, the following anomalous condi- AN5 Shuttle mode switch.
tions must be diagnosed (independently of the ECM AN6 Not used.
status).
AN4 Oil temperature sensor.
This check must be carried out at least every 10 ms
(longer pauses are not recommended). -- short to ground.
-- short to 5V or 12V or circuit open.
Anomalous condition description and reset AN7 Fuse 20.
5V SENSORS SUPPLY. -- short to ground or circuit open.
POWER SHUTTLE FAULT CODE PRIORITY
CODES FAULT PRIORITY CORRECTION EFFECT

11 CPDL_POT_LO_DISABLING_ERR 14 SL Dis
11 CPDL_POT_LO_ERR 75 Fixed Lim
12 CPDL_POT_HI_DISABLING_ERR 15 SL Dis
12 CPDL_POT_HI_ERR 74 Fixed Lim
13 UD_SW_ON_ERR 67 Auto None
14 C1_SW_HI_DIS_ERR 22 CP/SL Dis
14 C1_SW_HI_ERR 83 Fixed Model
15 C1_SW_LO_DIS_ERR 23 CP/SL Dis
15 C1_SW_LO_ERR 84 Fixed Model
16 G1_SW_HI_DIS_ERR 24 CP/SL Dis
16 G1_SW_HI_ERR 85 Fixed Model
17 G1_SW_LO_DIS_ERR 25 CP/SL Dis
17 G1_SW_LO_ERR 86 Fixed Model
18 CREEPER_ENG_SW_HI_ERR 47 Fixed Model
19 CREEPER_ENG_SW_LO_ERR 48 Fixed Model
21 CH_HARN_ERR 1 Fixed Crit.Dis
22 SOL_A_SHORT_DIS_ERR 39 CP/SL Dis
22 SOL_A_SHORT_ERR 97 Fixed Lim
23 SOL_B_SHORT_DIS_ERR 37 CP/SL Dis
23 SOL_B_SHORT_ERR 95 Fixed Lim
24 CL_UNCAL_ERR 100 Fixed Model
26 ERPM_HI_ERR 65 Fixed Model
27 ERPM_LO_ERR 66 Fixed Model
28 B_CL_UNCAL_ERR 101 Fixed Model
29 A_CL_UNCAL_ERR 102 Fixed Model
31 SOL_SHTL_SHORT_DIS_ERR 31 CP/SL Dis
31 SOL_SHTL_SHORT_ERR 90 Fixed Lim
32 SOL_HL_SHORT_DIS_ERR 33 CP/SL Dis
32 SOL_HL_SHORT_ERR 92 Fixed Lim
33 SOL_DUMP_SHORT_DIS_ERR 35 CP/SL Dis
33 SOL_DUMP_SHORT_ERR 98 Fixed Lim
35 SOL_DUMP_SHORT_12V_ERR 8 Fixed Crit.Dis
36 SOL_DUMP_OPEN_OR_GND_DIS_ERR 34 CP/SL Dis
36 SOL_DUMP_OPEN_OR_GND_ERR 99 Fixed Lim
37 CL_SW_OC_ERR 13 CP/SL Dis
38 SOL_B_SHORT_12V_ERR 9 Fixed Crit.Dis

39 SOL_B_OPEN_OR_GND_DIS_ERR 36 CP/SL Dis
39 SOL_B_OPEN_OR_GND_ERR 94 Fixed Lim
41 SOL_A_OPEN_OR_GND_DIS_ERR 38 CP/SL Dis
41 SOL_A_OPEN_OR_GND_ERR 96 Fixed Lim
42 SOL_A_SHORT_12V_ERR 11 Fixed Crit.Dis
43 SHTL_SYNCRO_SW_HI_DIS_ERR 18 CP/SL Dis
43 SHTL_SYNCRO_SW_HI_ERR 81 Fixed Lim
44 SHTL_SYNCRO_SW_LO_DIS_ERR 21 CP/SL Dis
44 SHTL_SYNCRO_SW_LO_ERR 82 Fixed Lim
46 FUSE_20_ERR 51 Auto Lim
47 CL_SW_HI_ERR 55 Fixed Model
48 CL_SW_LO_ERR 56 Fixed None
49 WHLSPD_SNR_HI_ERR 63 Fixed Model
51 TEMP_SNDR_OC_ERR 53 Auto Model
52 TEMP_SNDR_SC_ERR 54 Auto Model
53 V5_VREF_FAILED_HIGH 6 Fixed Crit.Dis
54 V5_VREF_FAILED_LOW 7 Fixed Crit.Dis
55 FORWARD_SW_HI_ERR 57 Auto None
56 FORWARD_SW_LO_ERR 58 Auto None
57 REVERSE_SW_HI_ERR 61 Auto None
58 REVERSE_SW_LO_ERR 62 Auto None
59 FNR_SW_DISAGREE_ERR 43 Auto Dis
61 HI_LO_SYNCRO_SW_HI_DIS_ERR 16 CP/SL Dis
61 HI_LO_SYNCRO_SW_HI_ERR 76 Fixed Lim
62 HI_LO_SYNCRO_SW_LO_DIS_ERR 17 CP/SL Dis
62 HI_LO_SYNCRO_SW_LO_ERR 77 Fixed Lim
63 SYNCRO_HL_ENG_ERR 40 SL/HI Dis
64 SYNCRO_SHTL_ENG_ERR 41 SL Dis
65 SOL_HL_OPEN_OR_GND_DIS_ERR 32 CP/SL Dis
65 SOL_HL_OPEN_OR_GND_ERR 91 Fixed Lim
66 SOL_SHTL_OPEN_OR_GND_DIS_ERR 28 CP/SL Dis
66 SOL_SHTL_OPEN_OR_GND_ERR 89 Fixed Lim
67 SOL_HL_SHORT_12V_DIS_ERR 27 CP/SL Dis
67 SOL_HL_SHORT_12V_ERR 87 Fixed Lim
68 SOL_SHTL_SHORT_12V_DIS_ERR 26 CP/SL Dis
68 SOL_SHTL_SHORT_12V_ERR 88 Fixed Lim
69 WHLSPD_SNRLO_ERR 64 Fixed Model

71 SYNC_START_UP_INIT_ERROR 93 Auto Dis
72 SYNC_POPPED_OUT_ERR 42 CP/SL Dis
73 V_12VF_FAILED_HI 2 Fixed Crit.Dis
74 V_12VF_FAILED_LOW 3 Fixed Crit.Dis
76 NVM_RD_ERR 68 Fixed Model
77 V8_VREF_FAILED_HIGH 4 Fixed Crit.Dis
78 V8_VREF_FAILED_LOW 5 Fixed Crit.Dis
81 PRESS_SW_OC_ERR 49 Fixed Model
82 PRESS_SW_SC_ERR 50 Fixed Model
SYMBOLS USED
CORRECTION column
Fixed the fault continues to be displayed (NO RESET).
Auto the fault is no longer displayed when the conditions that generated the fault are no longer present
(RESET).
SL the fault is no longer displayed by using the Shuttle (SL) and/or the clutch pedal (CP).
CP the fault is no longer displayed using the clutch pedal (CP).
Hi the fault is no longer displayed pressing the pushbutton (Hi).
Combinations of the aforementioned symbols are possible.
EFFECT column
Dis. Crit. the gears are critically disabled by this fault.
This fault can only be deleted by switching off the ECM.
Dis. the gears are disabled, the ”correction” column explains how the gears
can be enabled.
LIM the fault condition limits tractor operation.
e.g.: there are faults that disable certain functions.
Mod. the fault condition effects tractor operation.
e.g.: there are faults that make the tractor move slowly or abruptly.
CODE column
Contains the numerical code to display.
PRIORITY column
The apostrophe indicates that the CODE has already been used by a previously listed fault condition.
FAULT CODES INDICATION
In the event of an electrical or electronic fault, any
eventual anomalous conditions are indicated by the
illumination of an indicator lamp (1).
FAULTS CODE DECODING
The indicator (1) identifies the error code in six
phases:
1. 5 flashes in rapid succession to indicate imminent
transmission of the error code;
2. 2 second pause;
3. n... flashes to indicate the first figure of the fault MDD3231A
code;
4. 1 second pause; 55
5. n... flashes to indicate the second figure of the
fault code;
6. 3 second pause.
The control unit only indicates one code at a time, giv-
ing priority to the most serious faults.
If a higher priority fault occurs whilst a lower priority
fault is being displayed, the display sequence of
higher priorities will wait until the sequence in prog-
ress ends, before becoming active.
To check for the presence of other codes the fault
must be eliminated, allowing the control unit to pro-
ceed to the following fault.
IMPORTANT: If a fault disables the lift control func-

tion, the corresponding code will take precedence
over other codes that were previously indicated;
these codes will be saved by the system.
-- Example of the interpretation of fault code number 21 --
1st phase 2nd phase 3rd phase 4th phase 5th phase 6th phase
FFFFF pause FF pause F pause
code
second
transmission 2s first digit 2 1s 3s
digit 1
warning
fault code composition
p
21
CALIBRATION AND DIAGNOSTIC UNIT USE
Calibration unit use (CDU)
Specific remote diagnosis operations can be carried
out with the Calibration and Diagnosis Unit (CDU).
Errors code
If the Faults Detection Logic reads a fault condition,
the code will flash on the indicator. In this manner, the
fault condition can be displayed whilst in HH mode.
During calibration (H1 menu), certain faults may be
masked.
The CDU CNH294084 gives access to the following
menus:
H1 -- CLUTCHES A and B CALIBRATION)
H2 -- CLUTCHES A and B CALIBRATION VALUES
DISPLAY)
H3 -- SYSTEM CONFIGURATION
H4 -- SOFTWARE REVISION LEVEL
H5 -- CONTROL SWITCHES DIAGNOSTICS
H6 -- CLUTCH A FILL TIME MODIFICATION AND
DISPLAY
H7 -- CLUTCH B FILL TIME MODIFICATION AND
DISPLAY
H8 -- DELETE DATA SAVED IN THE NON--VOL-
ATILE MEMORY (EEPROM)
H9 -- VOLTMETER FUNCTIONS
HA -- CLUTCH PEDAL POSITION AND SWITCH
DISPLAY
HC -- TRANSMISSION OIL TEMPERATURE DIS-
PLAY
HD -- SHUTTLE SYNCHRONISER POSITION
NOT ACCESSIBLE ON TN STANDARD
HE -- GEAR CHANGE ADJUSTMENT
HF -- FAULTS SAVED IN THE ECM NON--VOLATI-
LE MEMORY
NOTE: The tractor can only be used in the H6, H7,

H9, HA, HC and HE menus.
Whilst other menus are being used the transmission
is disabled.
If tractor movement is detected whilst these menus
are in use, the menu will be interrupted and trans-
mission will be enabled; to re--enter the HH MENU,
stop the tractor and press key (1, fig. 58).
To exit from an active MENU, press key (1, fig. 58) to
return to the HH MENU.
If the menu allows tractor movement, stop the tractor
(speed = 0).
HH MENU ACCESS
WARNING
Put all gearshift levers in their neutral positions.
This is required because some H Menus allow
operation of the transmission.
1. Lift the hood (1) of the tractor.

2. Identify the CDU connector (2) located
underneath the hood at the right side of the tractor
forewall.
2
1
10007083
56
3. Turn the switch (1) to A (OFF) and connect the
CDU device 294084 to the black diagnosis
connector.
NOTE: Align the outer left ad right pins between the
male and female connector. They have a flat side to
orient the connector.
4. Turn the key switch to the “ON” position (B) (see
fig. NO TAG) while pressing down the “H Menu”
button (1), (see fig. 58). If the instrument panel
is not on, consult Section 55, electrical diagrams
as to which fuse provides power to the instrument
panel.
If the warning lights display an error code, but the
CDU does not light up and the H Menus can not 57
be accessed again, consult the electrical
diagrams as to which fuse provides power to the
diagnostic tool.
5. After a few seconds, the CDU display (2) shows
“H MENU”. Now the H Menu button can be
released. If the button was not held long enough
the CDU may display “NO COMM”. This also
occurs if the “H Menu” button is not held while
turning the key switch to the “ON” position.
6. Select the required H menu by pressing the H

MENU key (1) the correct number of times to dis-
play the relative code on the display (2), e.g.:
once to access H1, five times to access H5, etc.
Each time key (1) is pressed, the display (2) H5
shows the H code obtained, i.e.: H1, H2 etc.
Remember that after the HF MENU, the count re-
starts from HH.
After a brief pause (2 seconds) the ECM enters H
MENU
the procedure of the selected menu. 1 2 3 4
Explanations of the relative menus are noted on
the following pages. MDB0751A
If the operator presses key (1) whilst an H menu
is in use, the menu is abandoned and the display 58
(2) returns to the HH selection phase.
If the H code does not correspond with an active
H menu, the display (2) returns to HH and waits
for an ulterior selection.
7. Turn the key switch (1) to the “off” position (A) and
wait approximately 5 seconds to store the revised
data. The CDU can be re-entered by repeating
step #4.
NOTE: The functional software is always disabled

when the CDU is connected to the diagnosis connec-
tion, unless otherwise specifically noted. Consult the
description of the individual HH menus in order to un-
derstand why the functional software is disabled.
WARNING
Park the tractor on level ground in an unob- 59
structed area (in case of sudden movement).
Engage the handbrake, switch off all electrical
switches and the air conditioning system, if on.
Set the Shuttle control lever in neutral, the hy-
draulic lift lower arms down, the remote control
valve levers in neutral and switch off the engine.
Put safety wedges under the front and rear
wheels.
Check that the transmission oil temperature is
between 20 to 50 °C (68 to 122 °C).
Unless otherwise specified, the levers:
- Shuttle;
- Gear shift;
- Range gear;
- Creeper;
are in the NEUTRAL position.
H1 -- CLUTCHES A and B CALIBRATION
The H1menu provides access to Power Shuttle
clutches (A) and (B) calibration, reducing the engine
speed when the clutches start engaging. The ECM
reads engine RPM from the alternator to accomplish
this.
The calibration of the clutches is necessary when the
following has occurred:
• Poor transmission performance
• Solenoid valve has been replaced
• Erasure of non--volatile memory in the ECM
(using the H8 menu)
• ECM has been replaced
• After initial break-in period -- first 50 hrs.
Use the following procedure to calibrate the clutches.
1. Make sure the key switch (1) is in the “OFF”
position (A) and connect the CDU to the Power
Shuttle ECM as described previously in this
manual.
60
2. While holding the “HMENU” button (1) on the
CDU display (2), turn the key to the “START”
position (C).
3. After the tractor has gone through self diagnosis
and has started, release the “HMENU” button (1).
H1
“HMENU” should appear on the CDU display (2).
4. Press the “HMENU” button (1) once. “H1” should
appear on the CDU display (2). After a few H
seconds, “CALIBR” will appear momentarily on MENU
1 2 3 4
the CDU display (2) and then change to the
transmission fluid temperature.
MDB0751A
5. Make sure the parking brake is firmly set and

increase the engine speed to 1300 + 100 RPM. 61
6. Fully depress the clutch pedal (1).
62
7. Place the range lever (2) into the highest range
(B).
8. Place the gear selection lever into first gear (1).
63
9. Position the Power Shuttle FNR lever (1)to the
forward position.
10. Slowly release the clutch pedal, making sure the
tractor does not move.
64
CLUTCH A CALIBRATION
NOTE: If the diagnostic instrument displays an “U”
error code during the calibration procedure , refer to
the table at the end of this procedure in this section
to identify and remedy the problem. An example of
an error code would be U21 (engine speed lower than
1200 RPM).
1. Press and hold the down arrow (1) on the CDU.
Initially the CDU will display “STAB.RPM” (2),
then the initial value of the setting in milli--amps
(mA) (3).
2. Continue holding the down arrow (1) until the
engine speed reduces about 50 RPM and the STAB. RPM
final calibration setting flashes continuously (3).
An example would be : A=286mA
NOTE: The tractor may lurch, but not move. This value
and lurch represent the point the energized PWM 1
solenoid has provided enough hydraulic fluid to engage 2
the clutch pack. Hydraulic pressure at this point is not
full but approximately 2.7 -- 3.4 bar (40 -- 50 psi). 10006107
65
3. Release the down arrow (1) and the CDU display
should display the transmission oil temperature.
A = 286 mA
10006107
66
CLUTCH B CALIBRATION
NOTE: If the diagnostic instrument displays an “U”
error code during the calibration procedure , refer to
the table at the end of this procedure in this section
to identify and remedy the problem. An example of
an error code would be U21 (engine speed lower than
1200 RPM).
4. Press and hold the up arrow (1) on the CDU.
Initially the CDU will display “STAB.RPM” (2),
then the initial value of the setting in milli--amps 1
(mA) (3).
5. Continue holding the up arrow (1) until the engine
speed reduces about 50 RPM and the final STAB. RPM
calibration setting flashes continuously (3). An
example would be : A=286mA
NOTE: The tractor may lurch, but not move. This value
and lurch represent the point the energized PWM 2
solenoid has provided enough hydraulic fluid to engage
the clutch pack. Hydraulic pressure at this point is not
full but approximately 2.7 -- 3.4 bar (40 -- 50 psi). 10006107
67
6. Release the down arrow (1) and the CDU display
should display the transmission oil temperature.
7. Turn the key switch to the “OFF” position (A) to
store the (4) and (8) clutch values.
NOTE: If the tractor operation is abrupt after
calibrating the clutches, refer to the H6 and H7 menus A = 286 mA
to adjust the fill times for the clutches.
NOTE: As clutch components wear, the clutch
calibration and fill times will need adjusted
accordingly. 3
NOTE: Transmission output speed, engine RPM,
clutch pedal position, gear and range lever positions
are constantly monitored. Calibration can go on only 10006107
if the tractor is stationary, the Power Shuttle FNR 68
lever is not in neutral, the main (C1) and range (G1)
shift levers are not in neutral, and the clutch pedal is
released. If calibration conditions have not been met,
this will be displayed and the associated error code
will be flashed on the instrument panel. If the fault
condition is relevant to calibration, an “U” code will be
displayed on the CDU.
Calibration Error Codes

Code Cause Remedy
U19 Transmission oil temperature lower Drive tractor to increase transmission oil temperature
than 10_ C (50_ F) ∗
U20 Incorrect starting procedure Press and release clutch pedal
U21 Engine speed lower than 1200 RPM Increase engine speed
U22 Engine speed over 1400 RPM Decrease engine speed
U23 Power Shuttle control lever in neutral Place Power Shuttle control lever into the forward or
reverse position as required.
U24 Range selector in neutral Place range lever into highest range
U25 Gear selector in neutral Place gear lever into first gear
U26 Clutch pedal not fully raised Release clutch pedal fully
U27 Clutch pack (B) value lower than 230 Check solenoid value circuit and solenoid valve, replace
mA as necessary
U28 Clutch pack (B) value higher than 480 Check solenoid value circuit and solenoid valve, replace
mA as necessary. Test reverse solenoid hydraulic pressure
circuit.
U29 Clutch pack (A) value lower than 230 Check solenoid value circuit and solenoid valve, replace
mA as necessary
U30 Clutch pack (A) value higher than 480 Check solenoid value circuit and solenoid valve, replace
mA as necessary. Test reverse solenoid hydraulic pressure
circuit.
U31 Tractor is moving Engage parking brake
U32 Hi/Lo synchronizer not engaged Check synchronizer using the HD menu
(*) Between 10_ C (50_ F) and 20_ C (68_ F) the

CDU display will show “COLD OIL”. However, when
continuing to hold the up arrow or the down arrow key,
the calibration will continue.
H2 -- CLUTCHES A and B CALIBRATION
VALUES DISPLAY)
The H2 menu displays the calibration values
expressed in milli-amps (mA), for the “A” and “B”
hydraulic clutch solenoid valves. These values were
obtained by the ECM during the clutch calibration in
the H1 menu.
Use the following procedure to obtain the values:
1. Make sure the key switch (1) is in the “OFF” (A)
position and connect the CDU to the Power
Shuttle ECM, as described previously in this
manual.
2. While holding the “HMENU” button on the CDU,
turn the key switch to the “ON” (B) position.
3. Once the tractor has gone through diagnostics,
“HHMENU” should appear on the display.
Release the “HMENU” button.
69
4. Press the “HMENU” button (2) twice. “H2” should
appear on the CDU.
NOTE: The display automatically shows the “A” 3
clutch value.
2 H2
10006107
70
5. Press the up arrow (3) on the CDU to obtain the
value for the “B” clutch. The current stored value,
in mA, will be displayed. An example would be
B=290 mA. 3
6. Press the down arrow (4) on the CDU to obtain a 2 B = 290 mA

value for the “A” clutch. The current stored value,
expressed in mA, will be displayed. An example
would be: A=286 mA. 4
7. The mA range for each clutch must be between
230 mA and 480 mA (for either clutch).
10006107
8. Turn the key switch (1) to the “OFF” (A) position 71
or enter another menu by pressing the “HMENU”
button on the diagnostic instrument.
H3 -- SYSTEM CONFIGURATION
The H3 menu displays the tractor’s system
configuration, stored in the non-volatile memory
(NVM) menu after a tractor with a new ECM has been
initially started up. H3 also allows the transmission to
be configured manually.
1. Put the key switch (1) into the “OFF” position (A)
and connect the CDU to the Power Shuttle ECM
connector, as described previously in this
manual.
2. Hold the “HMENU” button (2) on the CDU and
turn the key switch (1) to the “ON” position (B).
72
3. After the tractor has gone through the
diagnostics, “HMENU” will appear on the display.
Release the “HMENU” button (2).
4. Press the “HMENU” button (2) three times. “H3”
will appear on the CDU display (3). After several
seconds the configuration stored will be 2 H3
displayed. One of the following configurations will
be shown:
• Pshuttle - Power Shuttle Transmission (8X8
or 16X16) 3
• Hi/Lo (does not apply to TN Standard) -
Power Shuttle Transmission with Hi/Lo
10006107
(32X16)
• Hi/Lo CR (does not apply to TN Standard) 73
- Power Shuttle Transmission with Hi/Lo and
Creeper (44X16)
• None - No configuration stored in memory,
occurs with the ECM replacement or erasure
of non-volitile memory (H8). Only detected at
first power on of ECM.
2 PSHUTTLE
10006107
74
NOTE: It is possible to select any configuration

available. Selection of the wrong configuration can
cause Error Codes to be displayed through the PS
Alarm lamp or causes tractor malfunctions. Selection
of the “NONE” will cause the ECM to conduct a
self-configuration at the next start-up. The self-con-
figuration check always gets performed when a
different ECM is installed, after H8 is cleared, and
whenever H3 configuration is set to “NONE”. The
ECM performs the self test by sending a signal out
through the harness and receives acknowledgement
of signs in from various sensors, switches, and
solenoids.
5. To quit the menu without modifying the
configuration, press the “HMENU” button (2) on
the CDU.
4
6. If the configuration displayed does not match the
configuration the tractor is equipped with, the
configuration can be modified manually by 2 PSHUTTLE
pressing the up arrow (4) until the correct
configuration is shown on the CDU.
7. When the correct configuration is shown, press 5
and hold the down arrow (5). The display (3) on 3
the CDU will start this sequence: “STORE 5s,
STORE 4s, STORE 3s, STORE 2s, STORE 1s,
STORED”. This shows the new configuration is 10006107
stored in the ECM. After the configuration has 75
been stored, release the down arrow (5) on the
CDU.
NOTE: If the down arrow (5) is released during the
store countdown, the latest changes to configuration
will not be stored and the CDU displays the previous
setting.
8. Turn the key switch (1) to the “OFF” position (A)
and wait for at least two seconds to save the
configuration into the non-volatile memory.
H4 - POWER SHUTTLE HARDWARE AND

SOFTWARE REVISION LEVELS
The H4 menu will display the revision level of the
software that is installed in the ECM. Use the
following procedure to display the revision levels:
1. Make sure the key switch is in the “OFF” (A)
Shuttle ECM connector, as described previously
in this manual.
76
4. Press the “HMENU” button four times. “H4”
should appear on the instrument display.
5. The instrument will display the following H4
information in a 8 second interval. Each
parameter will be displayed for 2 seconds and
then revert back to “HH MENU”.
• Product Identity (MA)
• Software Revision Level: (Release [00.01]))
• Hardware Level: (02.00) 10006107
• Manufacturer -- set valves (40)
77
NOTE: It is also a good practice to remove the
instrument panel in order to record the ECM part
number, module serial number and batch number.
6. When finished viewing, press the “HMENU”
button to enter another menu or turn the key
switch to the “OFF” (A) position.
H5 -- CONTROL SWITCH DIAGNOSIS

The H5 menu is for checking the status of the circuits
and control switches that are connected to the ECM.
The H5 menu allows inspection of each one of these
circuits for continuity and to check for transitions on
ECM inputs, either switch or analogue type, for
diagnostic purposes.
With reference to analogue inputs, “transition” means
that a certain threshold was exceeded. The letter “d”
and a number are displayed each time a transition
occurs.
The number displayed indicates in which circuit the
transition occurred. If same circuit has two
subsequent transitions, the message displayed
changes to “d0” when the second transition takes
place.
This routine also checks for Forward, Neutral and
Reverse button inconsistencies. The neutral button is
not tested separately through its own “d” number, as
the operator cannot induce neutral safety switch
transition in any manner without inducing it at the
same time on the Forward or Reverse buttons.
If the shuttle lever is moved with the clutch pedal
released, the neutral safety switch will originate a
transition also on the 12VD line, which is used to test
the clutch pedal button.
Following interaction among these buttons:
• The Forward and Reverse buttons should be
tested with the clutch pedal applied (down).
• The clutch pedal button should be tested with the
shuttle lever engaged (not in neutral).
• If the keystart switch is turned to the engine-on
position with the shuttle lever in neutral and the
clutch pedal down (normal start-up procedure), a
button inconsistency error may occur (exclusive-
ly in this diagnostic mode).
When a clutch pedal button transition occurs (pedal
is released), clutch pedal potentiometer calibration
values are checked and also button adjustment is
checked. Proceed as follows to guarantee adequate
checking.
NOTE: It is important to follow each of the procedures

as described, otherwise the display on the diagnostic
instrument will not show the correct reading.
manual.
78
NOTE: The clutch pedal should be up (released).
4. Place the Power Shuttle FNR lever, 1, in the

forward position.
79
5. Press the “HMENU” button five times. “H5”

should appear on the CDU display.
NOTE: d0 is always displayed first when H5 menu is
entered. To obtain the readings in the following
procedures the clutch pedal must be released and the
FNR lever must be in forward before entering H5 d0
menu.
6. Observe the display on the CDU while slowly
depressing the clutch pedal (at least two
seconds). The status of the potentiometer and
clutch switch is displayed. The display should
appear like this as the clutch pedal is being
10006107
depressed: d0 > d20 > d21 . d21 is displayed
when the clutch pedal “clicks” on the depressed 80
movement. If the clutch pedal is completely
released, the display will return to d20.
7. With the clutch pedal depressed, take the Power
Shuttle lever from forward and return the lever to
neutral. The display will change from d21 > d22.
Leave the tractor in neutral for a few seconds
while observing the display. The display should
continue to show d22 ; this helps to verify Error
Code 59.
8. While the clutch pedal is depressed, place the
Power Shuttle lever into reverse. The display
should change from d22 to d23.
9. Slowly release the clutch pedal while observing
the display on the CDU. The display should
change from reverse, d23, to the clutch switch,
d21, and then to the potentiometer, d20. This
verifies conditions related to Error Codes 11, 12,
47, and 48.
81
10. Place the gear selector lever (1) from neutral into
any gear. The CDU display should show d33.
Removing the gear selector lever from a gear
should cause a second transition in that circuit
and the display should show d0.
NOTE: If the gear lever is in gear when H5 menu is
entered, or another control or switch is moved while
the gear lever is engaged the readings may be
opposite from step 10.
82
11. Place the range control lever (1) from the neutral
position to any range. The CDU should display
1
d34.
NOTE: If any other control or switch is moved during

the shift, the “d” values may occur opposite as listed
above.
12. Stand up from the operator’s seat. This should

cause the CDU display to change to d36. Sitting
down on the seat will cause a second transition
and the display to change back to d0. 83
13. For d29 (Transmission Oil Temperature Sensor),
d30 (Transmission Oil Pressure Sensor), and
d35 (Transmission Wheel Speed Sensor) to be
displayed on the CDU, a transition must be
manually induced. This can be accomplished by
viewing the CDU as the sensor is unplugged and
plugged back together.
SUMMARY OF SWITCH AND ANALOGUE INPUTS
d. code Switch and Analogue Inputs

d.0 When H5 menu is first entered; and when a second transition occurs on the same switch
d.20 Clutch pedal potentiometer
d.21 Clutch pedal switch (Power Shuttle FNR lever must be in forward or reverse)
d.22 Power Shuttle FNR lever in forward position (Clutch must be depressed)
d.23 Power Shuttle FNR lever in reverse position (Clutch must be depressed)
d.29 Hydraulic oil temperature circuit (unplugged versus plugged in)
d.30 Hydraulic oil pressure circuit (engine off versus engine started)
d.32 Fuse supply to CDU (tool will not work if fuse is removed)
d.33 Main (C1) gear shift lever (in gear versus neutral)
d.34 Range (G1) gear shift lever (in gear versus neutral)
d.35 Wheel speed detection circuit (tractor moving)
d.36 Operator’s seat presence switch (stand-up)
Action Description Display
1 Enter the H5 menu with the clutch pedal released and the Shuttle lever in Forward. d0
Slowly press the clutch pedal (time > 2 seconds). The potentiometer status d20
2 change should be read first, followed by the pushbutton. d21
With the clutch pedal lowered, move the Shuttle lever from the Forward position
3 to neutral, to check the Forward selection pushbutton. d22
Leave the Shuttle lever in the neutral position for at least 1 second to check for
4 disagreement between the Forward/Neutral/Reverse pushbuttons (E59). (d22)
Holding down the clutch pedal, move the Shuttle lever from the neutral position to
5 Reverse, to check the relative pushbutton. d23
Release the clutch pedal slowly (time > 2 seconds).

The pushbutton status change should be read first. d21
6 Clutch pedal calibration is checked (E10, E11 and E12).
Clutch pedal pushbutton adjustment is checked (E47 and E48).
Finally, the potentiometer status change is read. d20
13 Carry out a status change on the oil temperature sensor. d29
15 Carry out a status change on the gear lever pushbutton. d33
16 Carry out a status change on the Range lever pushbutton. d34
17 Carry out a status change on the pressure switch. d30
18 Carry out a status change on the operator seat switch. d36

H6 -- CLUTCH (A) FILL TIME MODIFICATION

AND DISPLAY
IMPORTANT: The transmission is functional during
this menu.
The H6 menu displays the (A) clutch filling time and
allows change of the clutch filling time, if necessary.
(Full open solenoid valve for maximum flow of oil to
fill up clutch pack. The solenoid coil will receive full
voltage.)
If adjusting the clutch filling time due to poor or abrupt
tractor take off when the clutch is released, use the
following guidelines.
• Increase the clutch filling time if the tractor “jerks”
abruptly and then takes off.
• Decrease the clutch filling time if the tractor
“jerks”, then hesitates, and then takes off.
IMPORTANT: For best results, tractor should be
properly ballasted or configured according to what
tractor will be used for. Vehicle mass will affect shift
characteristics.
calibration and clutch fill time will need to be adjusted
accordingly.
manual.
turn the key switch, 1, to the “ON” (B) position.
84

4. Press the “HMENU” button six times. “H6” should
appear on the CDU display.
5. After a few seconds, the CDU will display a value A = 80ms
in milli-seconds (1/1000 second). For example,
the display may read: A=80ms. The clutch filling
time must be between 30 - 150 milli-seconds.
6. To change the filling time, be sure the Power
Shuttle control lever is in neutral and use the up
and down buttons to change the clutch filling time
10006107
by multiples of 10 ms. the factory default setting
is 70 ms. 85
IMPORTANT: The clutch must be fully released to
properly store the clutch filling time in the tractor
ECM.
7. With the clutch released, place the Power Shuttle
control lever in the forward position to store the
new value.
8. Return the Power Shuttle control lever to the
neutral position.
9. Turn the key switch to the “OFF” (A) position to
save the clutch fill time in the ECM.
NOTE: Fill time can also be adjusted by operating the
CDU while the tractor is running. The value is
changed and saved in the same manner as stated,
but the tractor is running, so ensure the gears are
neutral and parking brake set.
10. Disconnect the CDU from the tractor and test the
new clutch filling time by test driving the tractor in
a variety of situations. Adjust the clutch fill time
again, if necessary.
NOTE: The first fill time after adjustment may not be
reliable. Fill time should be tried several times to
accurately evaluate performance.
H7 - CLUTCH (B) FILL TIME

IMPORTANT: The transmission is functional during
this menu.
The H7 menu displays the (B) clutch filling time and
allows change of the clutch filling time, if necessary.
If adjusting the clutch filling time due to poor or abrupt
tractor take off when the clutch is released, use the
following guidelines.
• Increase the clutch filling time if the tractor “jerks”
abruptly and then takes off.
• Decrease the clutch filling time if the tractor
“jerks”, then hesitates, and then takes off.
IMPORTANT: For best results, tractor should be
properly ballasted or configured according to what
tractor will be used for. Vehicle mass will affect shift
characteristics.
calibration and clutch fill time will need to be adjusted
accordingly.
1. Make sure the key switch is in the “OFF” position
and connect the CDU to the Power Shuttle ECM,
as described previously in this manual.
86
4. Press the “HMENU” button seven times. “H7”

should appear on the CDU.
5. After a few seconds, the CDU will display a value
in milli-seconds (1/1000 second). For example,
the display may read: B=80ms. The clutch filling
time must be between 30 - 150 milli-seconds. B = 80ms
6. To change the filling time, be sure the Power
Shuttle control lever is in neutral and use the up
and down buttons to change the clutch filling time
by multiples of 10 ms. the factory default setting
is 70 ms.
IMPORTANT: The clutch must be fully released to
10006107
properly store the clutch filling time into the tractor
ECM. 87
7. With the clutch released, place the Power Shuttle
control lever in the forward position to store the
clutch fill time.
8. Return the Power Shuttle control lever to the
neutral position.
save the clutch fill time in the ECM.
NOTE: Fill time can also be adjusted by operating the
CDU while the tractor is running. The value is
changed and saved in the same manner as stated,
but the tractor is running, so ensure the gears are
neutral and parking brake set.
10. Disconnect the CDU from the tractor and test the
new clutch filling time by test driving the tractor in
a variety of situations. Adjust the clutch fill time
again, if necessary.
NOTE: The first fill time after adjustment may not be
reliable. Fill time should be tried several times to
accurately evaluate performance.
H8 - ERASURE OF DATA STORED IN THE

NON-VOLATILE MEMORY (NVM)
The H8 menu allows erasure of the data stored in the
non-volatile memory. This is useful in the case of
replacing the ECM from another tractor. The ECM’s
data from the previous tractor can be erased for the
tractor the ECM is going into. Use the following
procedure to erase the data stored in the ECM’s
non-volatile memory.
manual.

88

4. Press the “HMENU” button eight times. “H8”
5. After a few seconds “ERASE?” will be displayed ERASE?
on the on the CDU display.
6. To erase the non-volatile memory, press and hold
the down button on the CDU. The display will
show the following countdown sequence:
ERASE 5s, ERASE 4s, ERASE 3s, ERASE 2s,
ERASE 1s, ERASED. Releasing the up button at
anytime during this countdown will abort the 10006107
erasure of the non-volatile memory and revert
back to beginning of H8 mode. 89
7. Allow the ECM to self-configure by disconnecting
the CDU and turning the key switch to the “OFF”
(A) position. Then turn the key switch to the “ON”
(B) position and leave the switch on for at least 5
seconds. The ECM will find the tractor
configuration.
store the tractor configuration in the ECM.
9. (A) and (B) clutches must be calibrated (H1).
Error code(s) should have been erased, H9, and
if necessary, clutch fill times should be adjusted,
H6 and H7. Also double check configuration in H3
menu.
H9 -- VOLTMETER FUNCTIONS would display this is: 1 > 538. The values are not
The H9 menu allows inspection of individual circuits, actual voltage, amperage, or ohm measurements.
sensors, senders, switches, and solenoids showing The values are analogue/digital counts. When a
a channel number that corresponds to a particular channel measures frequency, the value is measured
circuit and a value which corresponds into a in “Hertz” (Hz).
measurement. An example of how the diagnostic tool
H9 Power Shuttle Channel Description

Channel/Description Circuit/Connector--Pin Information
1 Clutch Pedal Potentiometer Voltage CN2-20, Signal CN2-24, Ground CN2-29
2 Transmission Oil Temperature Sensor Signal CN2-25, Ground CN2-29
3 ECM 12V Key On Supply Voltage CN2-10 and CN2-34, Ground CN2-13
and CN2-14
4 ECM 12V Key START Supply Voltage CN1-15, Ground CN2-13 and CN2-14
5 Synchronizer Forward (Hi/Lo) Position Switch NOT USED TN Standard
6 Synchronizer Reverse (Shuttle) Position Switch NOT USED TN Standard
7 Clutch “B” PWM Solenoid Voltage CN1-11, Signal CN1-5
8 Clutch “A” PWM Solenoid Voltage CN1-10, Signal CN1-6
9 Power Shuttle FNR Lever Forward Switch Voltage CN2-20, Signal CN2-26
10 Power Shuttle FNR Lever Reverse Switch Voltage CN2-20, Signal CN2-27
11 Wheel Speed sensor Signal CN2-36, Ground CN2-29
12 Synchronizer Reverse (Shuttle) Solenoid NOT USED TN Standard
13 Synchronizer Forward (Hi/Lo) Solenoid NOT USED TN Standard
14 ECM 5V Input Sensor Supply Voltage CN2-20, Ground CN2-13 and CN2-14
15 ECM 12V Fuse Supply Voltage CN2-1, Ground CN2-13 and CN2-14
16 Main (C1) Gear Shift Lever Position Switch Voltage CN2-20, Signal CN2-4
17 Range (G1) Gear Shift Lever Position Switch Voltage CN2-20, Signal CN2-28
18 Creeper Engagement Switch NOT USED TN Standard
19 Wheel Speed Sensor Frequency Signal CN2-36, Ground CN2-29
20 Engine Speed Sensor Frequency (Alternator + W) Signal CN2-15
Use the following procedures to access the voltmeter

functions:

(A) and connect the CDU to the Power Shuttle
ECM, as described previously in this manual.
Ensure the parking brake is set.
90

“HMENU” should appear on the display. Release
the “HMENU” button.
4. Press the “HMENU” button nine times. “H9”
5. After a few seconds the first channel will be H9
indicated on the CDU display.
6. The channels, up to 24, may be displayed by
using the up and down buttons on the CDU.
Listed below are the channels and their values.
IMPORTANT: Transmission operation in enabled in
this menu. 10006107
NOTE: The status of the tractor (with key switch in the 91

“OFF”, “ON” (engine off), or “START” (engine
running) position) is listed behind the channel title in
parenthesis.
NOTE: Sometimes the clutch pedal position is not
stated. This is because the Power Shuttle FNR lever
may be stated in a certain position. The clutch pedal
depressed is the same as the Power Shuttle FNR
lever in neutral.
1. Clutch Pedal Potentiometer, (ON)
• released, (pedal up), 542 (maximum)
• depressed, (pedal down), 38 (minimum)
2. Transmission Oil Temperature Sensor, (ON)
1 → 538
NOTE: “HC Menu” will display transmission oil
temperature in degrees Celsius.
• At 0_ C (32_ F) 463 + 69
• At 30_ C (86_ F) 225 + 33
• At 60_ C (140_ F) 136 + 20 10006107
• At 90_ C (194_ F) 53 + 8 92
3. ECM +12 VF Keyed Battery Supply Voltage,
(ON)
• Battery charge at 9V (low charge,
prolonged cranking) 428
• Battery charge at 12V (normal) 595
• Battery charge at 16V (overcharge) 762
4. ECM +12VD Keyed Battery Voltage, (START)
a) Clutch pedal released and Power Shuttle
FNR lever in the forward or reverse position.
• Battery charge at 9V (low charge) 428
• Battery charge at 12V (normal) 595
• Battery charge at 16V (overcharge) 762
b) Power Shuttle FNR lever in the neutral posi-
tion or clutch pedal depressed 0-95
5. Synchronizer Forward (Hi/Lo) Position 10. Power Shuttle FNR Lever Reverse Switch,
Switch, (NOT USED TN Standard) (ON)
6. Synchronizer Reverse (Shuttle) Position • Neutral (21 min – 323 max) 170
Switch, (NOT USED TN Standard) • Forward (326 min – 900 max) 480
11. Wheel Speed Sensor Voltage, (START)

WARNING
The tractor will move when checking channels 7 NOTE: The tractor will not be moved during this test.
and 8. Be sure the area around the tractor is clear • Place range control lever into highest range
of people and objects before performing the • Place gear selector lever into first
following test, otherwise bodily injury, death or
• Place the Power Shuttle FNR lever into the
damage may occur.
forward position.
NOTE: For channels 7 and 8, reading will vary • Display with wheels not moving
depending upon clutch calibration values. (536 min – 831 max) 600
While Driving
NOTE: Allow at least six seconds for the CDU to
indicate an actual reading as solenoids ramp up to • 4 kph (2.4 mph) 3
proper amperage. Ramp up time is dependent upon • 8 kph (4.9 mph) 6
operating temperature of hydraulic fluid. • 20 kph(12.4 mph) 16
12. Synchronizer in Reverse (Shuttle) Solenoid,
7. Clutch (B) PWM Solenoid Driver Versus
(NOT USED TN Standard)
Status Sensed, (START)
13. Synchronizer in Forward (Hi/Lo) Position
• Release the parking brake Solenoid, (NOT USED TN Standard)
• Place range control lever into “A”
14. 5V input Sensor Supply Voltage, (ON)
• Place the gear selector lever into first
• (521 min. – 849 max.) 670
• Place the Power Shuttle FNR lever into
reverse for all transmissions
15. 12V Fuse Sensed Voltage, (ON)
• Display will read (200 min-400 max) 350
• Battery charge at 9V (low charge) 428
8. Clutch (A) PWM Solenoid Driver Versus • Battery charge at 12V (normal) 595
Status Sensed, (START) • Battery charge at 16 V (overcharge) 762
• Release the parking brake 16. Main (C1) Gear Shift Lever Position Switch,
• Place range control lever into “A” (ON)
• Place the gear selector lever into first • In neutral (516 min – 900 max) 680
• Place the Power Shuttle FNR lever into • In gear (21 min – 514 max) 340
forward position for all transmissions
17. Range (G1) Gear Shift Lever Position Switch,
• Display will read (200 min-400 max) 350 (ON)
9. Power Shuttle FNR Lever Forward Switch, • In neutral (516 min – 900 max) 680
(ON) • In gear (21 min – 514 max) 340
• Neutral (21 min – 323 max) 170 18. Creeper Control Lever (NOT USED TN
• Forward (326 min – 900 max) 480 Standard)
19. Wheel Speed Sensor Frequency, (ON) 20. Engine Speed Sensor Frequency
(Alternator+W), (START)
WARNING • 2500 RPM for software prior to 4.0 515
The tractor will move when checking channel 19. • 2000 RPM for software 4.0 to 5.0 33
Be sure the area around the tractor is clear of
people and objects before performing the • 2000 RPM for software 5.01 430
following test, otherwise bodily injury, death, or • 2000 RPM for software 6.0 415
damage may occur.
NOTE: There is no channel set aside in “H9” to check
NOTE: The reading displayed when the Power the dump solenoid, driver versus status sensed,
Shuttle FNR lever is placed in the forward position is circuit CN1-18 and CN1-2. A true test to this solenoid
dependent upon tires and the differential gear ratio is with an actual voltmeter with the red lead (+) to
the tractor is equipped with. CN1-18 and the black lead (-) to ground.
• Place range control lever into the highest • With FNR lever in neutral or with clutch pedal
range depressed -- solenoid energized 12V
• Place the gear selector lever into first 0-60 • With FNR lever NOT in neutral and with
• Place the Power Shuttle FNR lever into the clutch pedal released -- solenoid not
“forward” position 0-3000 energized 0V
HA-CLUTCH PEDAL POTENTIOMETER

AND STATUS SWITCH
The HA menu displays input values of both the clutch
pedal potentiometer and status switch. The clutch
pedal potentiometer position is expressed as a
percentage of the entire travel range while the clutch
pedal switch status is indicated by ON and OFF
during the travel of the pedal.
The transmission operation is enabled in this menu.
It is possible to drive the tractor and at the same time
record the clutch pedal potentiometer travel and
clutch pedal switch status from the CDU display. This
menu can also be viewed with the tractor stationary.
(A) and connect the CDU to the Power Shuttle
ECM, as described previously in this manual.
Ensure the parking brake is set.
93
“HMENU” should appear on the display. Release
the “HMENU” button.
4. Press the “HMENU” button until the “HA” appears
on the CDU display.
HA
10006107
94
5. Place the Power Shuttle FNR lever (1) into the

forward position.
NOTE: To run stationary test (if engine is running),
disengage the range lever and engage the parking
brake.
95
6. When the clutch pedal is released the percentage
should be 100% or 99 % ON.
When the clutch is fully depressed, the
percentage should be 0% or 1% OFF.
As the clutch pedal is being depressed, the 100% ON
display should change from “ON” to “OFF” before
5%.
As the clutch pedal is being released, the display
should change from “OFF” to “ON” before 15%.
“OFF” means the clutch pedal switch is open so 10006107

the dump solenoid is de-energized, oil is dumped
to sump from the clutch packs. 96
“ON” means the clutch pedal switch is closed so
the dump solenoid is energized, oil is supplied to
the clutch packs.
0% OFF
10006107
97
7. Turn the key switch to the “OFF” position to
disconnect the CDU or press the “HMENU”
button on the instrument to access another
menu.
CLUTCH PEDAL POTENTIOMETER

REPLACEMENT AND CLUTCH PEDAL
SWITCH ADJUSTMENT
If the clutch pedal potentiometer has been replaced,
the previous data for the clutch must be erased using
the H8 menu. Once the data has been erased, use
the following procedure to calibrate the new
potentiometer and adjust the switch.
1. Turn the key switch, 1, to the “ON” (B) position to
allow the ECM to perform the self configuration
(first start-up). Turn the key switch to the “OFF”
(A) position to save the configuration.
2. Turn the key switch back to the “ON” (B) position.
After a few moments the service transmission
light will begin to flash the error code for
“non-calibrated clutches”. Ignore this error for
now.
3. To calibrate the clutch pedal potentiometer limits,
fully depress the clutch pedal. Hold the clutch
pedal for a few seconds at the bottom travel limit. 1
4. Release the clutch pedal and allow the clutch to
remain at the top travel limit for a few seconds.
Turn the key switch to the “OFF” (A) position to 98
save the potentiometer limit calibration.
5. The clutch pedal potentiometer limit has been
calibrated. Now the clutch packs will need
calibrated. as described previously in the H1
menu description. The clutch pedal switch will
also need adjustment (see step 6--8).
NOTE: The clutch pedal switch is located under the
left lower dash cover on the inside of the clutch pedal 1
pivot.
6. To adjust the clutch pedal switch, 1, access the
HA menu using the CDU.
When the clutch pedal is released (raised), the
percentage should be 100% or 99% ON.
When the clutch is fully depressed, the
percentage should be O% or 1% OFF.
2
As the clutch pedal is being depressed, the
display should change from “ON” to “OFF” before
5%.
As the clutch pedal is being released, the display 50025110
should change from “OFF” to “ON” before 15%.
7. If the readings are not as specified, adjust the 99
clutch pedal switch by loosening the switch
mounting screws, 2, and moving the switch as
needed. The CDU display should change from
“ON” to “OFF” before 5% as the clutch is being
depressed and the display should change from
“OFF” to “ON” before 15% as the clutch pedal is
being released.
8. Make sure the mounting screws are tightened
once the clutch pedal switch is adjusted properly.
button to access another menu.
HC -- TRANSMISSION OIL TEMPERATURE

SENDER
NOTE: The transmission can be operated in this
mode.
The HC menu displays the temperature transmission
oil in degrees Celsius. To display the transmission oil
temperature, use the following procedure:
manual.
100
4. Press the “HMENU” button until “HC” appears on
the CDU.
T = 21°C
5. After a few seconds the display on the CDU will
indicate the temperature of the transmission oil,
in degrees Celsius. An example is: T = 21° C. The
temperature range is --40°C to +120°C (--40°F) to
+248°F).
10006107
button on the CDU to access another menu. 101
HD--HI/LO SYNCHRONIZER OPERATION

(NOT USED TN STANDARD)
NOTE: The transmission should be disabled, but
ensure the range lever is in neutral and the parking
brake is engaged.
The HD menu is used to inspect the operation of the
Forward/Reverse (Hi/Lo--Shuttle) Synchronizer and
will indicate the status of the synchronizer on the CDU
display. Use the following procedure to inspect the
F/R synchronizer operation.
2. Hold the “HMENU” button on the CDU and turn
the key switch (1) to the “START” position (C) and
start the engine.
102
diagnostics, “HMENU” will appear on the CDU
display. Release the “HMENU” button.
4. Press the “HMENU” button until “HD” appears on
the CDU display.
5. After a few seconds the CDU display will indicate HD
the status of the synchronizers position.
An example is: Pos = Hi/Lo, means the
synchronizer in the rear position ready for forward
travel, forward (Hi/Lo) position sensor pressed,
reverse (Shuttle) position sensor not pressed.
If the display indicates Pos = SHTL (or SHUT),
the synchronizer is in the front position for reverse 10006107
travel, reverse (Shuttle) position sensor pressed, 103
forward (Hi/Lo) position sensor not pressed.
If the display indicates Pos = UNKN, the ECM is
unsure of what position the synchronizer is in,
because the synchronizer did not engage
properly or is malfunctioning in some way,
normally Error Code 72.
NOTE: In case of failure of one or both synchronizer

position sensor, the message Pos = UNKN could be
displayed even if the synchronizer moves and
engages correctly. In this case, however, the Error
Code selected for the particular position sensor
should appear flashing on the instrument panel.
In normal conditions, the F/R synchronizer should
never be in the mechanical neutral position. If not
following a mechanical or electro-hydraulic problem,
the F/R synchronizer is always meshed with forward
or reverse gear even if the Power Shuttle FNR lever
or clutch pedal are in neutral. Mechanically there is
not a neutral synchronizer position. The Power
Shuttle FNR lever or clutch pedal are causing the
clutch packs to neutralize.
In normal conditions at engine start-up and during
ECM self-diagnosis, the F/R synchronizer is moved
automatically by the ECM to the opposite position
from tractor shut down. For example, if the
synchronizer is in the forward position, then it would
be moved to the reverse position during
self-diagnosis.
6. Increase the engine to 1200 – 1400 RPM and use
the up arrow and down arrow buttons on the CDU
to change the position of the synchronizer. The
CDU display will indicate the position of the
synchronizer.
7. Change the synchronizer position several times
to be sure the synchronizer is functioning
properly.
8. Turn the key switch to the “OFF” position (A) to
button on the CDU to access another menu.
HE -- GEAR CHANGE ADJUSTMENTS

The HE menu displays the speed threshold setting.
The ECM uses two shifting tables; one that is used
when the transmission is shifted above the speed
threshold setting; the other is used when the tractor
is shifted below the speed threshold setting. There
are three settings, as listed below.
• Low -- approximately 3 mph
• Med -- approximately 4 mph
• High -- approximately 8 mph
IMPORTANT: This value should not be changed as
it was set at the factory.
manual.
104
4. Press the “HMENU” button until “HE” appears on
the CDU display.
WST = MID
5. The display on the CDU will indicate one of the
following settings:
• High WST=HI (approx. 8 mph)
• Medium WST=MID (approx. 4 mph)
• Low WST=LOW (approx. 3 mph)
6. To change the engagement speed, use the up 10006107
and down buttons on the CDU until the desired
speed is indicated on the CDU display.
store the setting in the ECM. 105
HF-STORED ERROR CODES

When a fault is detected it is stored in the ECM
non-volatile memory and signalled by the indicator
lamp, (1). The HF menu allows access to Error Codes
that are stored in the non-volatile memory of the
ECM. Stored errors can be read and erased by using
the CDU. As soon as a fault condition is detected by
the ECM, the associated Error Code is saved into the
HF memory. Use the following procedure to access
the HF menu:
MDD3231A
106
2. Hold the “HMENU” button on the CDU and turn
the key switch (1) to the “ON” position (B).
107
diagnostics, “HMENU” will appear on the CDU
display. Release the “HMENU” button.
4. Press the “HMENU” button until “HF” appears on
the CDU display.
HF
5. The CDU display will indicate the last stored Error
Code. An example would be: E (9) =11.
6. The following key is used for Error Codes:
• E Error
• (9) Progressive storage channel of the
Error 10006107
• 11 Error Code number 108
7. The following will be displayed when there are no

Error Codes stored: E (1)=00 There is a
maximum of ten stored Error Codes. E(10) will be
the most recent Error Code.
NOTE: Do not hold the buttons that change the Error
Code displayed, otherwise the Error Codes may be E (1) = 00
erased.
8. If multiple Error Codes are present, use the up
arrow and down arrow buttons to view Error
Codes from other channels. Press them
momentarily when changing the Error Code
viewed.
10006107
9. Stored errors can be erased from the non-volatile
memory by pressing and holding the down arrow 109
button on the CDU until the following sequence is
displayed: ERASE 5s, ERASE4s, ERASE 3s,
ERASE 2s, ERASE 1s, ERASED.
NOTE: If the down arrow is released or the “HMENU”
is pushed during the erasure countdown, the
sequence is cancelled and the Error Codes are not
erased.
10. Release the down button once the errors have
been erased and turn the key switch to the “OFF”
position (A) for at least two seconds.
TROUBLESHOOTING FAULT CODES
WARNING calibration of the hydraulic clutches MENU H1

page 40.
Notes to help the operator make diagnosis and prob-
lem--solving easier. other requested calibration operations.
6. There are two types of faults:

1. The measurements taken to read: FAULT RESET: the fault will no longer be dis-
voltage; played if the cause has been eliminated or re-
resistance; paired, even without switching off the tractor, but
the relative code will be saved in the non--volatile
frequency. memory (see HF MENU);
must be carried out with a digital tester. NO FAULT RESET: the fault remains on the
alarm lamp when the cause is eliminated or
solved. To remove the fault display, stop then re-
NOTE: the resistance values shown are valid for a start the tractor. The fault will be saved (as a ”no
temperature of 20 o C (68 oF) (ambient temperature). fault reset”) in the non volatile memory (see HF
With higher or lower tractor temperatures, the relative MENU.
resistance values shown in the manual should vary
accordingly. 7. The connection references indicate: the wire di-
mension and colour, and the connection pin
number.
Example: 0.5 AB (2)
2. The “short to ground” message refers to a resis- 0.5 = wire diameter;
tance value of less than 5 ohm (Ω). AB = wire colour;
3. When a fault occurs, before carrying out any kind (2) = connection pin number.
of service operations, check that the specific con-
nections (ECM, sensors, switches, etc.) are cor- Electric Wire Color Coding
rectly connected. A -- Light Blue M -- Brown
A faulty connection could be the cause of incor- B -- White N -- Black
rect tractor operation. C -- Orange R -- Red
G -- Yellow S -- Pink
4. To facilitate problem solving, consult the ECM
H -- Grey V -- Green
electrical wiring diagram, shown on page 227.
L -- Blue Z -- Purple
5. If the ECM needs to be replaced, the following
operations must be carried out: 8. CN1--4 or CN2--25 on the ECM connections (85)
refer to the smaller connection (18 pin) or the
the H8 MENU function (cancellation of the resi- bigger connection (36 pin) and the relative pin
dent non--volatile memory); also check that the number.
self--configuration operation at the first start--up
(after ECM replacement) is correct; 9. The faults are listed in progressive order.
ECM LOCATION
The ECM (1) controls the POWER SHUTTLE.
PAGE LEFT BLANK

FAULT CODE 11 – CLUTCH PEDAL POTENTIOMETER (1) SIGNAL VOLTAGE SHORT TO

GROUND OR OPEN CIRCUIT.
NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner.
Conditions:
1. While tractor is being driven, signal voltage at ECM connector 2, pin 24 drops below 0.053 volts.
2. While tractor is in neutral, signal voltage at ECM connector 2, pin 24 drops below 0.053 volts.
Causes:
• Faulty wiring; circuit is shorted to ground or open between ECM connector 2, pin 20 and Clutch Pedal
Potentiometer, or between potentiometer terminals, or between Clutch Pedal Potentiometer and ECM
connector 2, pin 24. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted to ground
or open between potentiometer and any other 5 volt sensor.
• Faulty Clutch Pedal Potentiometer (1).
• Faulty ECM.
Tests:
• H9, Channel 1 value is below 30 counts.
• H5, doesn’t display transition between d0 and d20.
• HA, doesn’t read the correct percentage.
Effects of Condition 1:
• The Transmission Status Lamp is flashing.
• The clutch pedal doesn’t work.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever.
• An intermittent error is the same as the operator abruptly popping the Clutch Pedal.
• Transmission is limited; inching the tractor with the Clutch Pedal is not possible. Tractor can only be moved
using the Power Shuttle FNR Lever. Depressing the Clutch Pedal will stop the tractor and the error will revert
back to the first Condition.
Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.
NOTE: This error may also cause Error Code 37 and Error Code 48 to activate.
NOTE: The proper operation of the Power Shuttle FNR Lever and/or Clutch Pedal Switch guarantee activation
of the Dump Solenoid in order to safely control the transmission.
Replace the potentiometer.
Turn the starter key to the OFF position. Disconnect the potentiometer connection
Remove the left--hand panel under the (87).
dashboard. NO Using a digital tester, is the value between NO
Is connection (87) or the clutch pedal po- wires (V) and (N) (potentiometer side with
tentiometer wiring disconnected? the pedal released) ∼ 3.8 kΩ?
YES YES
Connect the connection and/or wiring. Is wire (S) (wiring side) in short to ground? NO
YES
Disconnect the control panel and the con-

nections (85) on the ECM.
Check the wiring between pin CN2--24 (S)
on connections (85) and connection (87) on
the potentiometer.
Eliminate the cause of the short to ground.
Is there electrical continuity between pin

CN2--24 (S) on connections (85) and con- NO
nection (87) (S) on the potentiometer?
YES
Replace the ECM.
Check the wiring and eliminate the cause of

the open circuit.
50025110
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
PIN 7 PIN 13 PIN 13 PIN 25
50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B)
110
Art Shown As If Sitting In Operator’s Seat
FAULT CODE 11
Tractor Side of Connector Potentiometer Side of Connector

87
0.5 AB (2) 1 C (2)

0.5 S (1) 1 V (1)
0.5 VN (3) 1 N (3)
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 12 – CLUTCH PEDAL POTENTIOMETER (1) SIGNAL VOLTAGE SHORT

TO 5 OR 12 VOLTS.
Conditions:
1. While tractor is being driven, voltage at ECM connector 2, pin 24 goes above 0.96 volts.
2. While tractor is in neutral, voltage at ECM connector 2, pin 24 goes above 0.96 volts.
Causes:
• Faulty wiring; circuit is shorted to 12 volts between ECM connector 2, pin 20 and Clutch Pedal Potentiometer,
or short to 5v across potentiometer terminals, or short to 5 or 12v between Clutch Pedal Potentiometer and
ECM connector 2, pin 24. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted
to 12v between potentiometer and any other 5 volt sensor.
• Faulty Clutch Pedal Potentiometer (1).
• Faulty ECM
Tests:
• H9, Channel 1 value is above 545 counts.
• HA, doesn’t read the correct percentage.
• The clutch pedal doesn’t work.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever.
• An intermittent error is the same as the operator abruptly popping the Clutch Pedal.
• Transmission is limited; inching the tractor with the Clutch Pedal is not possible. Tractor can only be moved
using the Power Shuttle FNR Lever. Depressing the Clutch Pedal will stop the tractor and the error will revert
back to the first Condition.
Recovery:
NOTE: This error may also cause Error Code 38 and Error Code 47 to activate.
NOTE: The proper operation of the Power Shuttle FNR Lever and/or Clutch Pedal Switch guarantee activation
of the Dump Solenoid in order to safely control the transmission.
Replace the potentiometer.
Turn the starter key to the OFF position. Disconnect connection (87) on the poten-
Remove the left--hand panel under the tiometer.
dashboard. NO Using a digital tester, is the value between NO
Is connection (87), or the clutch pedal po- wires (V) and (N) (potentiometer side with
tentiometer wiring, disconnected? the pedal released) ∼ 3.8 kΩ?
YES YES
Connect the connection and/or wiring. Disconnect the control panel and the con-
Is there electrical continuity between pin NO
CN2--29 (VN) on connections (85) and con-
nection (87) (VN) on the potentiometer?
YES
Turn the starter key to the OFF position.

Is there a reading of +5V or +12V between NO
CN2--24 (S) on connections (85) and
ground?
YES

the short to +5V or +12V.
Replace the ECM.

the open circuit.
50025110
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
111
FAULT CODE 12
Tractor Side of Connector Potentiometer Side of Connector

87
0.5 AB (2) 1 C (2)

0.5 S (1) 1 V (1)
0.5 VN (3) 1 N (3)
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 13 – HI AND LO BUTTONS PRESSED SIMULTANEOUSLY.

NOTE: Error Code is not triggered during clutch pack calibration, H1. Error is only shown on 32x16
transmissions.
NOTE: On a 32x16 the Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. They will flash in a
alternating manner.
Conditions:
• While driving or stationary, both Hi and Lo buttons pressed simultaneously longer than 0.5 seconds.
Causes:
• Operator pressed Hi and Lo Buttons at the same time.
• Hi or Lo Button Switch is stuck closed while the other button is pressed, (broken switch).
• Faulty wiring; circuit is shorted to 12 volts between Hi or Lo Button Switch and ECM connector 2, pin 3 or
22, when the opposition button is pressed.
Tests:
• H5, doesn’t display transition between d0 and d24 for Lo(Turtle) or d25 for Hi(Rabbit).
Effects:
• Speed shift will not take place.
• Transmission operates normally but not when Hi or Lo speed shift is conducted.
Recovery:
• Error will self-clear when Condition or Causes stop, but will be stored in HF.
• Cause must be resolved and cleared using the CDU, HF Menu.

Disassemble the HI and LO pushbuttons Remove the rear right--hand wheel.
knob. Disconnect the HI and LO pushbuttons con-
NO NO
Using a digital tester check the operation nection (89).
of the two pushbuttons. Is there a short circuit between the wires?
Is one of the two buttons in short? YES
YES
Replace the faulty pushbutton. the short circuit.
Replace the ECM.
89
0,5 AV (1)
1 C (2)
0,5 MB (3)
FAULT CODE 14 – MAIN (C1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO 5 OR 12
VOLTS.
Conditions:
2. While tractor is in neutral, voltage at ECM connector 2, pin 4 goes above 4.2 volts. Clutch Packs are at
maximum pressure but no movement seen while Main (C1) Gear Shift Switch reports to be engaged, (Wheel
Speed Sensor signal not reliable or tractor is not moving).
Causes:
• Faulty wiring; circuit is shorted to 12 volts between ECM connector 2, pin 20 and Main (C1) Gear Shift Switch,
or short to 5v volts between switch terminals, or short 5 or 12v between switch and ECM connector 2, pin
4. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted to 12v between switch and
any other 5 volt sensor.
• Faulty Main (C1) Gear Shift Switch.
• Faulty ECM.
Tests:
• Main (C1) Gear Shift Switch neutral position can not be detected.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal,
and Main (C1) Gear Shift Lever.
• Transmission is modified; Main (C1) Gear Shift Switch neutral position can not be detected, so ECM
assumes position is in gear. If Wheel Speed Sensor signal is not reliable, (Error Code 49), then transmission
is critically disabled, (no increase in wheel rotation when the Clutch Pack is at maximum pressure causes
the Dump Solenoid to be energized which returns oil to sump). If Wheel Speed Sensor signal is reliable, (no
error), then transmission attempt to move is conducted, (when the Clutch Pedal released and Power Shuttle
FNR Lever engaged into a direction).
Recovery:
(Gear position sensor X) If in short circuit, replace the pushbutton.
Turn the starter key to the OFF position. Disconnect connection (71) on pushbutton
Remove the rear right--hand wheel and (C1).
check connection (71) on pushbutton NO Position the gear lever in neutral and, using NO
(C1). a digital tester, measure the electrical resist-
Is there a short circuit between the wires? ance on the pushbutton.
Is the resistance ∼ 550 Ω?
YES
YES
Check the wiring and eliminate the cause
of the short circuit. Are wires (GL) and (AB) (wiring side) in NO
short?
YES

the short circuit between connection (71) on
the pushbutton and pins (C6) and (A7) on
the connection (69).
Does the fault persist?
YES

Check the wiring between pins CN2--4 (GL)
and CN2--20 (AB) on connections (85) with
pins (A7) (GL) and (C6) (AB) on connection
(69).
Eliminate the cause of the short circuit.
Replace the ECM.
71
1 AB
1 GL
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
112
FAULT CODE 14
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 15 – MAIN (C1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO GROUND
OR OPEN CIRCUIT.
Conditions:
1. While tractor is being driven, voltage at ECM connector 2, pin 4 goes below 0.7 volts.
2. While tractor is in neutral, voltage at ECM connector 2, pin 4 goes below 0.7 volts. Clutch Packs are at
maximum pressure but no movement seen while Main (C1) Gear Shift Switch reports to be engaged, (Wheel
Speed Sensor signal not reliable or tractor is not moving).
Causes:
• Faulty wiring; circuit is short to ground or open between ECM connector 2, pin 20 and Main (C1) Gear Shift
Switch, or across switch terminals, or between Main (C1) Gear Shift Switch and ECM connector 2, pin 4.
Or common 5 volt supply wire from ECM connector 2, pin 20 is shorted to ground or open between Main (C1)
Gear Shift Switch and any other 5 volt sensor.
• Faulty Main (C1) Gear Shift Switch.
• Faulty ECM.
Tests:
• H5, doesn’t display a transition between d0 and d33.
• Main (C1) Gear Shift Switch neutral position can not be detected.
and Main (C1) Gear Shift Lever.
• Transmission is modified; Main (C1) Gear Shift Switch neutral position can not be detected, so ECM
Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu 1.
(Range position sensor X)

Remove the rear right--hand wheel and
check connection (71) on pushbutton NO Connect the wires.
(C1).
Are the relative wires connected?
YES
Position the gear lever in neutral.

Using a digital tester, measure the electri- NO Replace the pushbutton if interrupted.
cal resistance on the pushbutton.
YES Disconnect the control panel and the con-
Wire (GL) (wiring side) in short to ground? NO Is there electrical continuity between pin NO
YES CN2--4 (GL) on connections (85), pin (A7)
(GL) on connection (69) and connection
Check the wiring and eliminate the cause (83) on the pushbutton?
of the short to ground. YES

CN2--20 (AB) on connections (85), pin (C6) NO
(AB) on connection (69) and connection
(71) on the pushbutton?
YES
Replace the ECM.

the open circuit.
71
1 AB
1 GL
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
113
FAULT CODE 15
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 16 – RANGE (G1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO 5 OR
12 VOLTS.
Conditions:
2. While tractor is in neutral, voltage at ECM connector 2, pin 28 goes above 4.2 volts. Clutch Packs are at
maximum pressure but no movement seen while Range (G1) Gear Shift Switch reports to be engaged,
(Wheel Speed Sensor signal not reliable or tractor is not moving).
Causes:
• Faulty wiring; circuit is shorted to 12 volts between ECM connector 2, pin 20 and Range (G1) Gear Shift
Switch, or short to 5 volts between switch terminals, or short 5 or 12v between switch and ECM connector
2, pin 28. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted to 12v between
switch and any other 5 volt sensor.
• Faulty Range (G1) Gear Shift Switch.
• Faulty ECM.
Tests:
• Range (G1) Gear Shift neutral position can not be detected.
and Range (G1) Gear Shift Lever.
• Transmission is modified; Range (G1) Gear Shift Switch neutral position can not be detected, so ECM
Recovery:
(Range position sensor Y) If in short circuit, replace the pushbutton.
Turn the starter key to the OFF position. Disconnect connection (70) on pushbutton
Remove the rear right--hand wheel and (G1).
check connection (70) on pushbutton NO Position the range lever in neutral and, us-
NO
(G1). ing a digital tester, measure the electrical re-
Is there a short circuit between the wires? sistance on the pushbutton.
YES Is the resistance ∼ 550 Ω?
YES
of the short circuit. Use a digital tester.
Are wires (BG) and (AB) (wiring side) in NO
short?
YES

the short circuit between connection (70) on
pushbutton and pins (B5) (GB) and (C6)
(AB) on connection (69).
YES

Check the wiring between pins CN2--28
(BG) and CN2--20 (AB) on connections (85)
with pins (B5) (GB) and (C6) (AB) on con-
nection (69).
Replace the ECM.
70
1 BG
1 AB
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
114
FAULT CODE 16
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 GR (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 17 - RANGE (G1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO
GROUND OR OPEN CIRCUIT.
Conditions:
1. While tractor is being driven, voltage at ECM connector 2, pin 28 goes below 0.7 volts.
2. While tractor is in neutral, voltage at ECM connector 2, pin 28 goes below 0.7 volts. Clutch Packs are at
maximum pressure but no movement seen while Range (G1) Gear Shift Switch reports to be engaged,
(Wheel Speed Sensor signal not reliable or tractor is not moving).
Causes:
• Faulty wiring; circuit is short to ground or open between ECM connector 2, pin 20 and Range (G1) Gear Shift
Switch, or across switch terminals, or between Range (G1) Gear Shift Switch and ECM connector 2, pin 28.
Or common 5 volt supply wire from ECM connector 2, pin 20 is shorted to ground or open between Range
(G1) Gear Shift Switch and any other 5 volt sensor.
• Faulty Range (G1) Gear Shift Switch.
• Faulty ECM.
Tests:
• Range (G1) Gear Shift neutral position can not be detected.
and Range (G1) Gear Shift Lever.
• Transmission is modified; Range (G1) Gear Shift Switch neutral position can not be detected, so ECM
Recovery:
(Range position sensor Y)

Remove the rear right--hand wheel and
check connection (70) on pushbutton NO Connect the wires.
(G1).
Are the relative wires connected?
YES
Position the gear lever in neutral.

YES Disconnect the control panel and the con-
Is wire (BG) (wiring side) in short to NO Is there electrical continuity between pin
ground? NO
CN2--28 (BG) on connections (85), pin (B5)
YES (BG) on connection (69) and connection
YES
of the short to ground.
CN2--20 (AB) on connections (85), pin (C6) NO
(AB) on connection (69) and connection
YES
Replace the ECM.

the open circuit.
70
1 BG
1 AB
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
115
FAULT CODE 17
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 18 -- VOLTAGE FROM CREEPER (N) SWITCH (CREEPER LEVER) TOO HIGH.
Conditions/Detection:
• Voltage at ECM connector 2, pin 21 goes above 4.2 volts.
Causes:
• Short circuit to +5 or +12 volts between creeper switch and ECM connector 2, pin 21.
• Short circuit at switch terminals or switch failure.
• ECM failure
Effects:
• Creeper lever neutral position cannot be detected
• The ECM will assume the creeper is engaged and the tractor will attempt to move when the shuttle lever is
in the forward or reverse position and the clutch pedal is raised.
Recovery:
• Error must be cleared using diagnostic tool.
If in short circuit, replace the pushbutton.
Disconnect connection (97**) on the push-

button.
Remove the rear left--hand wheel and the
Move the creeper lever to the engaged posi-
solenoid valves unit guard. NO NO
tion.
Check connection (97**) on the creeper
Using a digital tester, measure the electrical
pushbutton.
resistance on the pushbutton.
Is there a short circuit between the wires?
YES
YES
of the short circuit. Are wires (HG) and (AB) (wiring side) in NO
short circuit?
YES
Check the wiring between connection (97**)

on pushbutton and pins (C7) (HG) and (C6)
(AB) on connection (158).
YES

Check the wiring between pins CN2--21
(HG) and CN2--20 (AB) on connections
(129) with pins (C7) (HG) and (C6) (AB) on
connection (158).
Replace the ECM.
* * 97
0,5 AB
0,5 HG
PAGE LEFT BLANK

FAULT CODE 18
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 19 -- VOLTAGE FROM CREEPER (N) SWITCH (CREEPER LEVER) TOO LOW.
Conditions/Detection:
• Voltage at ECM connector 2, pin 21, goes below 0.7 volts.
Causes:
• Open circuit or short to ground between creeper switch and ECM connector 2, pin 21.
• Open circuit or short to ground between switch terminals or faulty switch.
• ECM failure
Effects:
• Creeper lever neutral position cannot be detected
• The ECM will assume the tractor is in gear and the tractor will attempt to move when the shuttle lever is in
the forward or reverse position and the clutch pedal is raised.
Recovery:
• Error must be cleared using diagnostic tool.
Replace the pushbutton if interrupted.
Disconnect connection (97**) on the creep-

Turn the starter key to the OFF position. er pushbutton.
Remove the rear left--hand wheel and the Move the creeper lever to the engaged posi-
solenoid valves unit guard. NO tion. NO
Check connection (97**) and the creeper Using a digital tester, measure the electrical
pushbutton wiring. resistance on the pushbutton.
Is the wiring disconnected? Is the resistance ∼ 550 Ω?
YES
YES
Connect the wiring.
Is wire (HG) (wiring side) in short to ground? NO
YES

the short to ground.

CN2--21 (HG) on connections (129), pin NO
(C7) (HG) on connection (158) and connec-
tion (97**) on the pushbutton?
YES

CN2--20 (AB) on connections (129), pin NO
(C6) (AB) on connection (158) and connec-
tion (97**) on the pushbutton?
YES
Replace the ECM.

the open circuit.
* * 97
0,5 AB
0,5 HG
PAGE LEFT BLANK

FAULT CODE 19
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 21 – CHASSIS HARNESS

NOTE: The 32x16 transmission will use this FAULT CODE for F/R Synchronizer circuit and dump circuit. The
16x16 & 8x8 transmissions will use this FAULT CODE for just the dump circuit.
NOTE: Power Shuttle ECM to PS ECM Harness connected at CN1 and CN2, located under the instrument panel.
PS ECM Harness to PS Transmission Side Harness connected at CN 9 A-D or CN 9 (24 pins), located under
the hood on engine side of firewall. PS Transmission Side Harness to Dump Solenoid and F/R Synchronizer
Position Sensors located on left side of transmission by the Power Shuttle Control Valve.
Conditions:
• While tractor is being driven or in neutral, open circuit between Power Shuttle ECM Harness and Power
Shuttle Transmission Side Harness hinders communication.
Causes:
• Faulty wiring; connector between PS ECM Harness and PS Transmission Side Harness disconnected, (at
firewall). Connector between Dump Solenoid and Transmission Side Harness is disconnected. Connector
between F/R Synchronizer Position Sensors and Transmission Side Harness is disconnected. Connector
between F/R Synchronizer Solenoids and Transmission Side Harness is disconnected. Connectors and pins
are pinched, loose, or corroded.
Tests:
• H9, channels related to the dump solenoid, F/R Synchronizer Position Sensors, and F/R Synchronizer
Solenoids will not display the correct count.
• H5, related to the dump solenoid, F/R Synchronizer Position Sensors, and F/R Synchronizer Solenoids
doesn’t display the correct transition between d0 and the corresponding d value.
• HF, would display open circuit FAULT CODEs related to the dump solenoid, F/R Synchronizer Position
Sensors, and F/R Synchronizer Solenoids.
Effects:
• Transmission is critically disabled; but can be re-enabled by cycling the Ignition Switch, (shutting off the
tractor).
Recovery:

Raise the engine hood. NO Connect connection (158).
Is connection (158) connected?
YES
Remove the rear left--hand wheel and the solenoid

valves unit guard. NO Connect the wiring.
Is the wiring on the solenoid valve connected?
YES
Disconnect the control panel. Connect the connections correctly

Are connections (129) on the ECM correctly con- NO
(129).
nected?
YES
Replace the ECM.

PAGE LEFT BLANK

FAULT CODE 21
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 22 – CLUTCH PACK (A) PULSE WIDTH MODULATED SOLENOID COIL SHORT
CIRCUIT.
NOTE: On all transmissions Clutch Pack (A) is the front pack, used for forward movement, controlled by the
bottom, horizontal solenoid on the Power Shuttle Control Valve Assembly. Clutch Pack (B) is the rear pack, used
for reverse movement, controlled by the top, horizontal solenoid on the Power Shuttle Control Valve Assembly.
Conditions:
1. While tractor is being driven in Forward, the Clutch Pack (A) PWM Solenoid has a short circuit.
2. While tractor is being driven in Reverse, the Clutch Pack (A) PWM Solenoid has a short circuit.
Causes:
• Faulty wiring; circuit is shorted between the ECM connector 1, pin 10 and ECM connector 1, pin 6 wires, or
across the two solenoid coil terminals.
• Faulty Clutch Pack (A) PWM Solenoid Coil.
• Faulty ECM.
Tests:
• Clutch Pack (A) becomes inoperable.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.
• Transmission is limited; Clutch Pack (A) becomes inoperable; meaning the output signal from ECM, CN1-10
sends voltage to the input signal ECM, CN1-6 without going through the solenoid coil. PWM Solenoid can
not be electrically controlled to pressurize and de-pressurize the Clutch Pack. Transmission will only operate
in Reverse.
Recovery:

valves unit guard.
Disconnect connection (75) on the clutch solenoid NO Replace the solenoid valve coil if in
valve (A). short.
Is the electrical resistance on the solenoid valve
coil, measured with a digital tester, ∼ 10 Ω?
YES
Wires (AR) and (AN) (wiring side) are in short. NO Replace the ECM.
YES
Check the wiring between connection (75) on the

solenoid valve and pins (C8) (AR) and (B7) (AN) on
connection (69).
YES
Disconnect the control panel and the connections

(85) on the ECM.
Check the wiring between pins CN1--10 (AR) and
CN1--6 (AN) on connections (85) with pins (C8)
(AR) and (B7) (AN) on connection (69).
75
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
116
FAULT CODE 22
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 23 – CLUTCH PACK (B) PULSE WIDTH MODULATED SOLENOID COIL SHORT
CIRCUIT.
NOTE: Two Conditions/Detection will trigger this error code.
Conditions:
1. While tractor is being driven in Reverse, the Clutch Pack (B) PWM Solenoid has a short circuit.
2. While tractor is being driven in Forward, the Clutch Pack (B) PWM Solenoid has a short circuit.
Causes:
• Faulty wiring; circuit is shorted between ECM connector 1, pin 11 and ECM connector 1, pin 5 wires, or across
the two solenoid coil terminals.
• Faulty Clutch Pack (B) PWM Solenoid Coil.
• Faulty ECM.
Tests:
• Effects of Condition 1:
• Clutch Pack (B) becomes inoperable.
• Transmission is limited; Clutch Pack (B) becomes inoperable; meaning the output signal from ECM, CN1-11
sends voltage to the input signal ECM, CN1-5 without going through the solenoid coil. PWM Solenoid can
not be electrically controlled to pressurize and de-pressurize the Clutch Pack. Transmission will only operate
in Forward.
Recovery:

valves unit guard.
Disconnect connection (74) on the clutch solenoid NO Replace the solenoid valve coil if in
valve (B). short.
Is the electrical resistance on the solenoid valve
YES
Wires (BN) and (BR) (wiring side) are in short. NO Replace the ECM.
YES

solenoid valve and pins (A5) (BN) and (A8) (BR) on
connection (69).
YES

(85) on the ECM.
Check the wiring between pins CN1--11 (BN) and
CN1--5 (BR) on connections (85) with pins (A5)
(BN) and (A8) (BR) on connection (69).
74
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
117
FAULT CODE 23
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 24 – CLUTCH PACK (A) AND (B) PULSE WIDTH MODULATED SOLENOIDS
ARE NOT CALIBRATED.
Conditions:
• Clutch Pack Solenoid Calibration Values are out of acceptable range or are not registered.
Causes:
• Clutch Pack Calibration procedure, (H1) has not been performed after replacing a Power Shuttle ECM.
• Clutch Pack Calibration procedure, (H1) has not been performed after conducting a Non-Volatile Memory
Erasure, (H8), using the CDU.
• Clutch Pack Calibration procedure, (H1) has not been performed after replacing the Clutch Pack (A and B)
PWM Solenoids.
• During Clutch Pack Calibration procedure, (H1) a Calibration “U” Error occurs preventing the completion of
a Calibration procedure.
• Faulty ECM; Clutch Pack Calibration values are corrupt in the Electrically Erased Programmable Read Only
Memory, (EEPROM) and Non-Volatile Memory, (NVM), [H8].
Tests:
• H2, doesn’t display calibration values within range 230 to 480 mA.
Effects:
• Transmission is modified; feathering with the Clutch Pedal will be poor, jerky, or impossible. Directional
modulation between forward and reverse using the Power Shuttle FNR Lever will be poor, jerky, or
impossible.
• Error code will remain active until a Clutch Pack Calibration procedure, (H1), is completed.
Recovery:
NOTE: This error code will mask Errors Code 28 and Error Code 29 to prevent ECM memory saturation.
H1
H
MENU
1 2 3 4
MDB0751A
FAULT CODE 26 – ENGINE RPM FREQUENCY SIGNAL TOO HIGH.
Conditions:
• For 3 consecutive seconds, the Engine RPM is greater than 3500, with Wheel Speed Sensor indicating
movement, while a Clutch Pack receives full pressure.
Causes:
• Faulty alternator drive belt. Faulty alternator.
• Faulty Engine high idle setting.
• Frequency between alternator W+ terminal and ECM connector 2, pin 15 is too high.
Tests:
• H9, channel 20 is higher than given value.
Effects:
• Unable to conduct Calibration of Clutch Packs (H1).
• Transmission is modified; ECM assumes 2300 Engine RPM, so engine performance may be reduced at
other RPM levels.
Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF menu.
NOTE: This error will NOT self-clear even if the engine RPM is returned to correct speed.

Is wire (R) on alternator socket (W) correctly con- NO Connect the wire correctly.
nected?
YES
Start the engine and accelerate to 1000 rpm (make

sure that the recharging lamp is off).
Using a digital tester measure the frequency at the Replace the alternator if the frequen-
NO
alternator output between la socket (W) and cy value is much higher.
ground.
Is the frequency ∼ 200 Hz?
YES
Replace the ECM (1).

FAULT CODE 27 – ENGINE RPM FREQUENCY SIGNAL TOO LOW.
Conditions:
• For 3 consecutive seconds, the Engine RPM is less than 500, with Wheel Speed Sensor indicating
movement, while a Clutch Pack receives full pressure.
Causes:
• Faulty Alternator Drive Belt.
• Faulty Alternator.
• Faulty Engine low idle setting.
• Faulty wiring; circuit open between Alternator W+ terminal and ECM connector 2, pin 15, or short to ground
between ECM connector 2, pin 15 and alternator (W+) terminal, or short to 12 volts between ECM connector
2, pin 15 and alternator {W+) terminal.
Tests:
• H9, channel 20 is lower than given value.
Effects:
• Unable to conduct Calibration of Clutch Packs (H1)
• Transmission is modified; ECM assumes 2300 Engine RPM, so engine performance may be reduced at
other RPM levels.
Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF menu.
NOTE: This error will NOT clear even if the engine RPM is throttle down to correct speed.
Turn the starter key to the ON position. NO Replace the lamp bulb.
Is the alternator recharge lamp ON?
YES
Start the engine and accelerate to 1200 Check the recharge system.
rpm. NO
Is the recharge lamp OFF?
YES
YES
Is wire (R) on the alternator socket (W) Connect the wire correctly
NO
correctly connected?
YES
Is the alternator socket (W) wire (R) in NO

short to ground?
YES

YES
Bring engine speed to 1000 rpm.

Using a digital tester, measure the fre-
quency at the alternator output between
the socket (W) and ground. NO Replace the alternator.
Is the frequency ∼ 200 Hz?
YES

the open circuit.
CN2--15 (R) (wiring side) and the alterna-
tor socket (W)?
YES
Replace the ECM.

ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
118
FAULT CODE 27
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 28 – CLUTCH PACK (B) NOT CALIBRATED.

NOTE: This error code will not be displayed during clutch calibration procedure, (H1). “U” codes are used during
H1 procedure for notification of incorrect calibration values. Use tool 294084 to access the H1 menu.
Conditions:
• While key switch is in the “ON” position the ECM detects that the Clutch Pack (B) is not calibrated.
Causes:
• Clutch Pack (B) Calibration procedure, (H1) has not been performed after replacing a Power Shuttle ECM.
• Clutch Pack (B) Calibration procedure, (H1) has not been performed after conducting a Non-Volatile Memory
• Clutch Pack (B) Calibration procedure, (H1) has not been performed after replacing the Clutch Pack (A and
B) PWM Solenoids.
• During Clutch Pack (B) Calibration procedure, (H1) a Calibration “U” Error occurs preventing the completion
of a Calibration procedure.
• Faulty ECM; Clutch Pack (B) Calibration values are corrupt in the Electrically Erased Programmable Read
Only Memory, (EEPROM) and Non-Volatile Memory, (NVM), [H8].
Tests:
Effects:
• Transmission is modified; Reverse will be affected by the poor performance of Clutch Pack (B).
Recovery:
H1
H
MENU
1 2 3 4
MDB0751A
FAULT CODE 29 – CLUTCH PACK (A) NOT CALIBRATED.

NOTE: This error code will not be displayed during clutch calibration procedure, (H1). “U” codes are used during
H1 procedure for notification of incorrect calibration values. Use tool 294084 to access the H1 menu.
Conditions:
• While key switch is in the “ON” position the ECM detects that the Clutch Pack (A) is not calibrated.
Causes:
• Clutch Pack (A) Calibration procedure, (H1) has not been performed after replacing a Power Shuttle ECM.
• Clutch Pack (A) Calibration procedure, (H1) has not been performed after conducting a Non-Volatile Memory
• Clutch Pack (A) Calibration procedure, (H1) has not been performed after replacing the Clutch Pack (A and
B) PWM Solenoids.
• During Clutch Pack (A) Calibration procedure, (H1) a Calibration “U” Error occurs preventing the completion
of a Calibration procedure.
• Faulty ECM; Clutch Pack (A) Calibration values are corrupt in the Electrically Erased Programmable Read
Only Memory, (EEPROM) and Non-Volatile Memory, (NVM), [H8].
Tests:
Effects:
• Transmission is modified; Forward will be affected by the poor performance of Clutch Pack (A).
Recovery:
H1
H
MENU
1 2 3 4
MDB0751A
FAULT CODE 31 – REVERSE (SHUTTLE) SYNCHRONIZER SOLENOID COIL SHORT

CIRCUIT.
NOTE: Error is only for 32x16. The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. They will
flash in a alternating manner.
Conditions:
1. While the tractor is being driven in reverse the Reverse (Shuttle) Synchronizer Solenoid has a short circuit.
2. While the tractor is in neutral the Reverse (Shuttle) Synchronizer Solenoid has a short circuit.
Causes:
• Faulty wiring; circuit shorted between ECM connector 1, pin 17 and ECM connector 1, pin 3 wires, or across
the two coil terminals.
• Faulty Reverse (Shuttle) Synchronizer Solenoid Coil.
• Faulty ECM.
Tests:
• H9, channel 13 value is below 0 counts.
• Transmission is limited; Reverse Side of the F/R Synchronizer Piston becomes inoperable; meaning the
solenoid can not hydraulically pressurize and de-pressurize the piston. If the Synchronizer was already in
the reverse position then the tractor will move in reverse. But once the Synchronizer is moved into the forward
position it will not be able to shift it back into reverse.
Recovery:

valves unit guard.
Disconnect connection (65) on the Shuttle syn- Replace the solenoid valve coil if in
NO
chroniser solenoid valve. short.
Is the solenoid valve coil electrical resistance,
measured with a digital tester, ∼ 7 Ω?
YES
Are wires (SN) and (SG) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES

solenoid valve and pins (B4) (SN) and (C4) (SG) on
connection (158).
YES

(129) on the ECM.
Check the wiring between pins CN1--17 (SN) and
CN1--3 (SG) on connections (129) with pins (B4)
(SN) and (C4) (SG) on connection (158).
PAGE LEFT BLANK

FAULT CODE 31
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 32 – FORWARD (HI-LO) SYNCHRONIZER SOLENOID COIL SHORT CIRCUIT.

NOTE: Error is only for 32x16. The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. They will
flash in a alternating manner.
Conditions:
1. While the tractor is being driven in forward the Forward (Hi-Lo) Synchronizer Solenoid has a short circuit.
2. While the tractor is in neutral the Forward (Hi-Lo) Synchronizer Solenoid has a short circuit.
Causes:
• Faulty wiring; circuit shorted between ECM connector 1, pin 16 and ECM connector 1, pin 4 wires, or across
• Faulty Forward (Hi-Lo) Synchronizer Solenoid Coil.
• Faulty ECM.
Tests:
• H9, channel 12 value is below 0 counts.
• Transmission is limited; Forward Side of the F/R Synchronizer Piston becomes inoperable; meaning the
solenoid can not hydraulically pressurize and de-pressurize the piston. If the Synchronizer was already in
the Forward position then the tractor will move in forward. But once the Synchronizer is moved into the
Reverse position it will not be able to shift it back into forward.
Recovery:

valves unit guard.
Disconnect connection (67) on the Shuttle syn- Replace the solenoid valve coil if in
NO
chroniser solenoid valve. short.
Is the electrical resistance of the solenoid valve
YES
Are wires (GN) and (GR) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES

solenoid valve and pins (B2) (GN) and (C1) (GR)
on connection (158).
YES

(129) on the ECM.
Check the wiring between pins CN1--16 (GN) and
CN1--4 (GR) on connections (129) with pins (B2)
(GN) and (C1) (GR) on connection (158).
PAGE LEFT BLANK

FAULT CODE 32
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 33 – DUMP SOLENOID COIL SHORT CIRCUIT.

Conditions:
1. While the tractor is being driven in forward or reverse the Dump Solenoid has a short circuit.
2. While the tractor is in neutral the Dump Solenoid has a short circuit.
Causes:
• Faulty wiring; circuit is shorted between ECM connector 1, pin 18 and ECM connector 1, pin 2 wires, or across
• Faulty Dump Solenoid Coil.
• Faulty ECM.
Tests:
• No H Menu for diagnostic check.
• Transmission is limited; Dump Solenoid stays energized, meaning the output signal from ECM, CN1-18
sends voltage to the input signal ECM, CN1-2 without going through the solenoid coil. The Clutch Packs (A
or B) can not be hydraulically de-presserised. Transmission will still operate by using other Clutch Pack
solenoids to bleed off hydraulic pressure when shuttle or speed shift is conducted.
Recovery:

valves unit guard.
Disconnect connection (77) on the dump solenoid Replace the solenoid valve coil if in
NO
valve. short.
Is the electrical resistance of the solenoid valve
YES
Are wires (ZB) and (ZN) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES

solenoid valve and pins (B8) (ZB) and (B3) (ZN) on
connection (69).
YES

(85) on the ECM.
Check the wiring between pins CN1--18 (ZB) and
CN1--2 (ZN) on connections (85) with pins (B8)
(ZB) and (B3) (ZN) on connection (69).
77
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
119
FAULT CODE 33
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 35 – DUMP SOLENOID OR ECM DRIVER SHORT CIRCUIT TO 12 VOLTS.
Conditions:
• While the tractor is being driven in forward or reverse, the Dump Solenoid becomes energized by a short
to 12 volts.
Causes:
• Faulty wiring; circuit short to 12 volts between ECM connector 1, pin 18 and the solenoid coil terminal, or
across solenoid coil terminals, or between ECM connector 1, pin 2 and solenoid coil terminal.
• Faulty ECM; internal ECM driver is shorted to 12 volts.
Tests:
Effects:
• Dump Solenoid short circuit to 12 volts instead of being 0 volts; therefore keeping the Dump Solenoid
energized which causes Clutch Pack (A or B) to be de-pressurized.
tractor).
Recovery:

nections (85) on the ECM. Is there a reading of +12V between pin
Turn the starter key to the ON position. NO CN1--2 (ZN) on connections (85) (wiring NO
Is there a reading of +12V between pin side) and ground?
CN1--18 (ZB) on connections (85) (wiring YES
side) and ground?
YES Check the wiring between CN1--2 (ZN) on
connections (85), pin (B3) (ZN) on connec-
Check the wiring between pin CN1--18 tion (69) and connection (77) on the sole-
(ZB) on connections (85), pin (B8) (ZB) on noid valve.
connection (69) and connection (77) on
the solenoid valve.
Eliminate the cause of the short circuit to
+12V. Replace the ECM.
77
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
120
FAULT CODE 35
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 36 – DUMP SOLENOID SHORT CIRCUIT TO GROUND OR OPEN CIRCUIT OR

ECM DRIVER OPEN.
Conditions:
1. While the tractor is being driven in forward or reverse, the Dump Solenoid has a short to ground or open
circuit.
2. While the tractor is in neutral the Dump Solenoid has a short to ground or open circuit.
Causes:
• Faulty wiring; circuit short to ground or open between ECM connector 1, pin 18 and the solenoid coil terminal,
or across the two coil terminals, or between ECM connector 1, pin 2 and the solenoid coil terminal.
• Faulty ECM; internal ECM driver is open or short to ground.
Tests:
• Transmission is limited; Dump Solenoid stays de-energized. The Clutch Packs (A or B) can not be
hydraulically de-pressurized. Transmission will still operate by using other Clutch Pack solenoids to bleed
off hydraulic pressure when shuttle or speed shift is conducted.
Recovery:

Turn the starter key to the OFF position. the open circuit.
solenoid valves unit guard.
Disconnect connection (77) on the dump Replace the solenoid valve coil if inter-
NO
solenoid valve. rupted.
Using a digital tester, measure the electri-
cal resistance of the solenoid valve coil.
Is the resistance ∼ 7.5 Ω?
YES
Is wire (ZB) on the solenoid valve wiring in NO nections (85) on the ECM.
NO
short to ground? Is wire (ZN) on the solenoid valve wiring in
YES short to ground?
YES
of the short to ground?
Lift the engine bonnet and disconnect con-

nection (69).
(B8) (ZB) and connection (77) on the sole-
noid valve?
YES

NO
(B3) (ZN) and connection (77) on the sole-
77 noid valve?
YES

CN1--18 (ZB) on connections (85) and pin
(B8) (ZB) on connection (69)? NO
YES

CN1--2 (ZN) on connections (85) and pin NO
(B3) (ZN) on connection (69)?
YES
Replace the ECM.

ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
121
FAULT CODE 36
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 37 – CLUTCH PEDAL SWITCH (1) OPEN CIRCUIT.

NOTE: This error may be triggered by Error Code 11.
Conditions:
• For 1 second, when Clutch Pedal is released, (switch closed), the Clutch Pedal Potentiometer is above 30%,
while Power Shuttle FNR Lever is not in neutral, (Voltage is being supplied to ECM connector 2, pin 18), and
with 12 volts not present at ECM connector 1, pin 15.
Causes:
• Faulty wiring; circuit open between ECM connector 1, pin 15 and Clutch Pedal Switch.
• Faulty Clutch Pedal Switch (1).
• Clutch Pedal Switch (1) is sticking, (cold weather condition).
• Clutch Pedal Switch (1) is miss adjusted.
Tests:
• H9, channel 4 is too low.
• H5, does not change from “d0” to “d21”.
• HA, doesn’t display correct values.
Effects:
• Transmission is disabled, but can be re-enabled by cycling the Clutch Pedal.
Recovery:
(Clutch pedal double switch 1)

Remove the left--hand panel under the dashboard. Connect the connection and/or wiring.
Is connection (86) and/or the switch wiring con- NO
nected?
YES
Disconnect connection (86) on the switch.

Using a digital tester, check the double switch. NO Replace the switch.
Does it work?
YES

(85) on the ECM.
Check the wiring and eliminate the
Is there electrical continuity between pin CN1--15 NO
cause of the open circuit.
(RN) on connections (85) and connection (86) on
the switch?
YES
Replace the ECM.
50025110
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
122
FAULT CODE 37
86
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 38 – CLUTCH PACK (B) PULSE WIDTH MODULATED SOLENOID OR ECM
DRIVER SHORT CIRCUIT TO 12 VOLTS.
Conditions:
• While tractor is being operated the Clutch Pack (B) Pulse Width Modulated Solenoid becomes energized
by a short circuit to 12 volts.
Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 1, pin 11 and the solenoid coil terminal or
Tests:
• H9, Channel 7 value stays constant and is above 480 counts.
Effects:
• The Clutch Pack (B) PWM Solenoid Coil remains energized, keeping clutch engaged. Non authorized 12
volt can only be stopped by activating the Dump Solenoid, (neutral PS FNR Lever or depressed Clutch
Pedal). The transmission is disabled to ensure the operator is not placed in a dangerous situation where the
tractor can not be stopped.
• Transmission is critically disabled, but can be re-enabled by cycling the Ignition Switch, (shutting off tractor).
Recovery:
Cause must be resolved and error must be cleared
using the CDU, HF Menu.

Turn the starter key to the ON position. NO CN1--5 (BR) on connections (85) (wiring NO
CN1--11 (11) (BN) on connections (85) YES
(wiring side) and ground?
YES Check the wiring between CN1--5 (BR) on
connections (85), pin (A8) (BR) on connec-
(BN) on connections (85), pin (A5) (BN) noid valve.
on connection (69) and connection (74) on
the solenoid valve.
74
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
123
FAULT CODE 38
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 39 – CLUTCH PACK (B) PULSE WIDTH MODULATED SOLENOID SHORT
CIRCUIT TO GROUND OR OPEN CIRCUIT OR ECM DRIVER OPEN.
Conditions:
1. While tractor is being driven Reverse, the Clutch Pack (B) PWM Solenoid has a short to ground or open
circuit.
2. While tractor is being driven Forward, the Clutch Pack (B) PWM Solenoid has a short to ground or open
circuit.
Causes:
• Faulty wiring; circuit is short to ground or open between ECM connector 1, pin 11 and the solenoid coil
terminal, or across the two solenoid coil terminals, or between ECM connector 1, pin 5 and the solenoid coil
terminal.
• Faulty ECM; internal ECM driver is open or short to ground.
Tests:
• H9, Channel 7 value is below 200 counts
• Transmission is limited; Clutch Pack (B) becomes inoperable; meaning the PWM Solenoid can not
hydraulically pressurize and de-pressurize the Clutch Pack. Transmission will only operate in Forward.
Recovery:
Turn the starter key to the OFF position. Check the wiring and eliminate the cause of
Remove the rear left--hand wheel and the the open circuit.
Disconnect connection (74) on the clutch
solenoid valve (B). Replace the solenoid valve coil if inter-
NO
Using a digital tester, measure the electri- rupted.
YES
Is wire (BN) on the solenoid valve wiring nections (85) on the ECM.
NO NO
in short to ground? Is wire (BR) on the solenoid valve wiring in
YES
nection (69).
(A5) (BN) and connection (74) on the sole- NO
noid valve?
YES

(A8) (BR) and connection (74) on the sole- NO
noid valve?
YES

CN1--11 (BN) on connections (85) and pin NO
(A5) (BN) on connection (69)?
74 YES

CN1--5 (BR) on connections (85) and pin NO
(A8) (BR) on connection (69)?
YES
Replace the ECM.

ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
124
FAULT CODE 39
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 41 – CLUTCH PACK (A) PULSE WIDTH MODULATED SOLENOID SHORT
CIRCUIT TO GROUND OR OPEN CIRCUIT OR ECM DRIVE OPEN.
Conditions:
1. While tractor is being driven Lo-Forward, the Clutch Pack (A, Lo-Forward) PWM Solenoid has a short to
ground or open circuit.
2. While tractor is being driven Hi-Forward or Reverse, the Clutch Pack (A, Lo-Forward) PWM Solenoid has
a short to ground or open circuit.
Causes:
• Faulty wiring; circuit short to ground or open between ECM connector 1, pin 10 and the solenoid coil terminal,
or across the two solenoid coil terminals, or between ECM connector 1, pin 6 and the solenoid coil terminal.
• Faulty Clutch Pack (A, Lo-Forward) PWM Solenoid Coil.
• Faulty ECM; internal ECM Driver is open or short to ground.
Tests:
• H9, Channel 8 value is below 200 counts
• Clutch Pack (A) becomes inoperable; meaning the PWM Solenoid can not hydraulically pressurize and
de-pressurize the Clutch Pack.
• Transmission is limited; Clutch Pack (A) becomes inoperable; meaning the PWM Solenoid can not
hydraulically pressurize and de-pressurize the Clutch Pack. Transmission will only operate in Hi-Forward or
Reverse.
Recovery:
Turn the starter key to the OFF position. Check the wiring and eliminate the cause of
Remove the rear left--hand wheel and the the open circuit.
Disconnect connection (75) on the clutch Replace the solenoid valve coil if inter-
NO
solenoid valve (A). rupted.
Using a digital tester, measure the electri-
YES
Is wire (AR) on the solenoid valve wiring nections (85) on the ECM.
NO NO
in short to ground? Is wire (AN) on the solenoid valve wiring in
YES

nection (69).
(C8) (AR) and connection (75) on the sole-
noid valve?
YES

(B7) (AN) and connection (75) on the sole- NO
noid valve?
YES

CN1--10 (AR) on connections (85) and pin
(C8) (AR) on connection (69)? NO
75 YES

CN1--6 (AN) on connections (85) and pin NO
(B7) (AN) on connection (69)?
YES
Replace the ECM.

ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
125
FAULT CODE 41
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 42 – CLUTCH PACK (A) PULSE WIDTH MODULATED SOLENOID OR ECM
DRIVER SHORT CIRCUIT TO 12 VOLTS.
Conditions:
• While tractor is being operated the Clutch Pack (A) Pulse Width Modulated Solenoid becomes energized
by a short circuit to 12 volts.
Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 1, pin 10 and the solenoid coil terminal or
• Faulty Clutch Pack (A) PWM Solenoid Coil.
Tests:
• H9, Channel 8 value stays constant and is above 480 counts.
Effects:
• The Clutch Pack (A) PWM Solenoid Coil remains energized, keeping clutch engaged. Non authorized 12
volt can only be stopped by activating the Dump Solenoid, (neutral PS FNR Lever or depressed Clutch
Pedal). The transmission is disabled to ensure the operator is not placed in a dangerous situation where the
tractor can not be stopped.
• Transmission is critically disabled, but can be re-enabled by cycling the Ignition Switch, (shutting off tractor).
Recovery:

Turn the starter key to the ON position. NO CN1--6 (AN) on connections (85) (wiring NO
CN1--10 (AR) on connections (85) (wiring YES
side) and ground?
YES Check the wiring between CN1--6 (AN) on
connections (85), pin (B7) (AN) on connec-
(AR) on connections (85), pin (C8) (AR) noid valve.
on connection (69) and connection (75) on
the solenoid valve.
75
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
126
FAULT CODE 42
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 43 – SYNCHRONIZER SHUTTLE (REVERSE) POSITION SWITCH (T) SIGNAL

VOLTAGE SHORT TO 5 OR 12 VOLTS.

alternating manner. On 16x16 & 8x8 the Transmission Status Lamp is the Gear with a Slash lamp. It will flash.
NOTE: On the 32x16 transmission, the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Position Switches
are located on the left side of the transmission between the Power Shuttle Control Valve and the Service Control
Valve. The Synchronizer Shuttle (Reverse) Position Switch is toward the rear of the tractor. The Synchronizer
Hi-Lo (Forward) Position Switch is toward the front of the tractor.
Conditions:
1. While the Power Shuttle FNR Lever is in the reverse position, voltage at the ECM connector 2, pin 23 is above
4.2 volts.
2. While the Power Shuttle FNR Lever is in the neutral position, voltage at the ECM connector 2, pin 23 is above
4.2 volts.
Causes:
• Faulty wiring; short to 12 volts between ECM connector 2, pin 20 and Synchronizer Shuttle (Reverse)
Position Switch, or short to 5 v across switch terminals, or short to 5 or 12 v between Synchronizer Shuttle
(Reverse) Position Switch and ECM connector 2, pin 23. Or common 5 volt sensor supply wire from ECM
connector 2, pin 20 is shorted to 12v between switch and any other 5 volt sensor.
• Faulty Synchronizer Shuttle (Reverse) Position Switch (T).
• Faulty ECM.
Tests:
• H9, channel 6 is above 860 counts.
• H5 doesn’t display “d27”.
• HD displays “unkn”.
• Transmission is limited; only Synchronizer Hi-Lo (Forward) Position Switch is available (forward movement).
Any shuttle into reverse will not work. Transmission is neutralized whenever Power Shuttle FNR is put into
reverse position. Then ECM will look for detection of Synchronizer Hi-Lo (Forward) Position Switch and move
synchronizer to forward position.
Recovery:

valves unit guard.
Disconnect connection (59) on pushbutton. NO If in short, replace the pushbutton.
Using a digital tester, measure the electrical resist-
ance on the pushbutton.
Is the resistance 500 ÷ 3000 Ω?
YES
Are wires (AB) and (HL) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES
Check the wiring between connection (59) on

pushbutton , pin (C3) (HL) and pin (C6) (AB) on
connection (158).
YES

(129) on the ECM.
Check the wiring between pin CN2--23 (HL) on
connections (129) and pin (C3) (HL) on connection
(158) or between pin CN2--20 (AB) and pin (C6)
(AB).
59
0,5 AB
0,5 HL
PAGE LEFT BLANK

FAULT CODE 43
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 44 – SYNCHRONIZER SHUTTLE (REVERSE) POSITION SWITCH (T) SIGNAL

VOLTAGE IS SHORT TO GROUND OR OPEN CIRCUIT.

alternating manner. On 16x16 & 8x8 the Transmission Status Lamp is the Gear with a Slash lamp. It will flash.
Conditions:
1. While the Power Shuttle FNR Lever is in the reverse position, voltage at the ECM connector 2, pin 23 is below
0.7 volts.
2. While the Power Shuttle FNR Lever is in the neutral position, voltage at the ECM connector 2, pin 23 is below
0.7 volts.
Causes:
• Faulty wiring; circuit shorted to ground or open between ECM connector 2, pin 20 and Synchronizer Shuttle
(Reverse) Position Switch, or between switch terminals, or between Synchronizer Shuttle (Reverse) Position
Switch and ECM connector 2, pin 23. Or common 5 volt sensor supply wire from ECM connector 2, pin 20
is shorted to ground or open between switch and any other 5 volt sensor.
• Faulty Synchronizer Shuttle (Reverse) Position Switch (T).
• Faulty ECM.
Tests:
• H9, channel 6 is below 143 counts.
• Transmission is disabled, but can be re-enable by cycling the Power Shuttle FNR Lever or Clutch Pedal.
• Transmission is limited; only Synchronizer Hi-Lo (Forward) Position Switch is available (forward movement).
Any shuttle into reverse will not work. Transmission is neutralized whenever Power Shuttle FNR is put into
reverse position. Then ECM will look for detection of Synchronizer Hi-Lo (Forward) Position Switch and move
Recovery:

the open circuit.
solenoid valves unit guard. NO Connect the connection and/or wiring.
Is the wiring and connection (59) on the
pushbutton connected?
YES
Disconnect connection (59) on the push-

button.
YES Raise the engine hood.
Disconnect connection (158).
Is wire (HL) (wiring side) in short to NO Is there electrical continuity between con- NO
ground?
nection (59) on pushbutton (HL) and pin
YES
(C3) (HL) on connection (158)?
Disconnect the control panel and connec- YES
tions (129) on the ECM.
Check the wiring between connection Is there electrical continuity between con-
(59), pin (C3) (HL) on connection (158) nection (59) on pushbutton (AB) and pin NO
and pin CN2--23 (HL) on connections (C6) (AB) on connection (158)?
(129). YES
Disconnect the control panel and connec-
CN2--23 (HL) on connections (129) and pin
(C3) (HL) on connection (158)?
YES

CN2--20 (AB) on connections (129) and pin NO
(C6) (AB) on connection (158)?
YES
Replace the ECM.

59
0,5 AB
0,5 HL
PAGE LEFT BLANK

FAULT CODE 44
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 46 – FUSE ERROR

NOTE: This fuse protects the ECM connector 2, pin 1 circuit. The actual fuse number is 15. The circuit is keyed
12 volts. The fuse is a 5 amp.
Conditions:
• When tractor on, ECM detects voltage at ECM connector 2, pin 1 is low while voltage at ECM connector 2,
pin 10 is high.
Cause:
• Faulty wiring; circuit open between battery and key switch or between key switch and fuse, or across fuse,
or between fuse and ECM connector 2, pin 1.
• Faulty Fuse.
• Faulty ECM.
Tests:
• H9, channel 15 is below 428.
• H5, won’t show “d20”.
Effects:
• Transmission will be limited; ECM Calibration / Diagnostic Unit (CDU) will not work.
Recovery:

Turn the starter key to the OFF position. nections (85) on the ECM.
Remove the left--hand guard located un- Turn the starter key to the ON position.
der the control panel. NO
Is there a reading of +12V between pin NO
Is fuse F15 (Section 55, Chapter 5, page CN2--21 (HG) on connections (85) and
2 blown)? ground?
YES YES
Replace the fuse. Replace the ECM.
Check the wiring between connection (85)

and the fusebox.
Eliminate the cause of the open circuit.
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 47 – CLUTCH PEDAL SWITCH (1) SET TOO HIGH.
Conditions:
• For 1 second, when Clutch Pedal Potentiometer is above 15%, while the Power Shuttle FNR lever not in
neutral, (ECM connector 2, pin 18 should have 12 volts), with the clutch pedal released and the clutch pedal
switch isn’t open, (ECM connector 1, pin 15 should have 12 volts).
Causes:
• Faulty wiring; open circuit between Power Shuttle FNR Lever, (neutral switch) and ECM connector 1, pin
15, (Error Code 37, when pedal is released).
• Faulty Clutch Pedal Switch (1). (Error Code 37, when pedal is released).
• Improperly adjusted switch (1).
Tests:
• H9, channel 1 is higher than 542 during release.
• HA, during clutch pedal release, the Clutch Pedal Switch (1) changes from off to on after 15%.
Effects:
• Transmission is modified; clutch pedal inching maneuver may be jerky and occur at a higher clutch pedal
position.
Recovery:

Connect the connection and/or wiring.
Connect tool 294084 to the diagnosis
socket (black), press the H MENU key
and turn the starter switch to the ON posi- Remove the left--hand panel under the
tion, then select the HA MENU. dashboard. NO
NO
Move the Shuttle lever to forward gear Is the wiring and connection (86) con-
and fully press down the clutch pedal. nected?
When the clutch pedal is released, the YES
message switches from “OFF” to “ON”?
YES Disconnect connection (86) on the switch
and check. NO
Does it work?
YES

CN1--15 (RN) on connections (85) and con-
nection (86) on the switch?
YES
Remove the left--hand panel under the

Press the clutch pedal fully down and re- dashboard.
lease slowly. Position the double switch on the relative
The message switches from “OFF” a NO slots, so that the message switches be-
“ON” in correspondence to a percentage tween “OFF” and “ON” in correspondence
value of 10 to 15? to a set value (10 to 15 %).
YES
Replace the ECM.

the open circuit.
Replace the switch.
50025110
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
127
FAULT CODE 47
86
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 48 – CLUTCH PEDAL SWITCH (1) SET TOO LOW.
Conditions:
• For 1 second, when Clutch Pedal Potentiometer is below 5%, while the Power Shuttle FNR lever in neutral,
(ECM connector 2, pin 18 shouldn’t have 12 volts), with the clutch pedal depressed and the clutch pedal
switch is open, (ECM connector 1, pin 15 shouldn’t have 12 volts).
Causes:
• Faulty wiring; circuit short to 12 volts between Power Shuttle FNR Lever, (neutral switch) and ECM connector
1, pin 15.
• Faulty Clutch Pedal Switch (1).
• Improperly adjusted / sticky switch (1).
Tests:
• H9, channel 1 is lower than 38 during depression.
• HA, during clutch pedal depression, the Clutch Pedal Switch (1) changes from on to off after 5%.
Effects:
• No effect to normal operation except using the clutch pedal will not neutralize the transmission, (de-energize
the clutch pack solenoids). The Power Shuttle FNR Lever will have to be used to make tractor move.
Recovery:
Connect tool 294084 to the diagnosis socket

(black), press the H MENU key and turn the starter
Remove the left--hand panel under
switch to the ON position, then select the HA
the dashboard.
MENU.
Position the double switch on the rel-
Move the Shuttle lever to forward gear. NO ative slots, so that the message
Press and release the clutch pedal, the percentage
switches between “ON” and “OFF” in
value displayed is∼ 100 with the “ON” message.
correspondence to a set value (5 to
By slowly pressing the clutch pedal, the message
8%).
switches from “ON” to “OFF” in correspondence to
a percentage value of 5 to 8?
YES
Replace the ECM.
HA
H
MENU
1 2 3 4
MDB0751A
50025110
FAULT CODE 49 – WHEEL SPEED SENSOR (Aa) VOLTAGE SHORT TO 5 OR 12 VOLTS.
Conditions:
• The ECM detects voltage is above 4.25 volts at ECM connector 2, pin 36.
Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 2, pin 36 and Wheel Speed Sensor (Aa)
terminal, or short to 5v across sensor terminals, or short to 5 or 12v between Wheel Speed Sensor (Aa) and
ECM connector 2, pin 29.
• Faulty Wheel Speed Sensor.
• Faulty ECM.
Tests:
• H5, doesn’t display “d35”.
Effects:
• Transmission is modified; Power Shuttle FNR lever may not shuttle directions correctly. Acceleration or
tractor movement may not be sensed by ECM during Automatic Take Off (ATO).
Recovery:

Remove the rear left--hand wheel. NO Connect the connection and/or
Is connection (76) and the sensor wiring con- wiring.
nected?
YES
Disconnect sensor connection (76).

Using a digital tester, measure the sensor electri- NO Replace the sensor if interrupted.
cal resistance.
YES
Raise the engine hood.

Is there electrical continuity between connection NO
(76) (HB) on the sensor and pin (B3) (HB) on con- cause of the open circuit.
nection (69)?
YES
Is there electrical continuity between connection

(76) (VN) on the sensor and pin (A4) (VN) on con- NO
nection (69)?
YES

(85) on the ECM.
Is there electrical continuity between pin (B3) (HB) NO
on connection (69) and pin CN2--36 (HB) on con-
nections (85)?
YES
Is there electrical continuity between pin (A4) (VN)

on connection (69) and pin CN2--29 (VN) on con- NO
nections (85)?
YES
Turn the starter key to the ON position.

Is there a reading of +12V between pin CN2--29 NO Replace the ECM.
(VN) (wiring side) on connections (85) and
ground?
YES (Speed sensor Aa)
Check the wiring and eliminate the cause of the
short to +12V.
76
VN
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
128
FAULT CODE 49
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 51 – TRANSMISSION TEMPERATURE SENDER (Bb) OPEN CIRCUIT.
Conditions:
Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 2, pin 25 and Transmission Temperature
Sender terminal, or short to 5v across sender terminals, or short to 5 or 12v between Transmission
Temperature Sender and ECM connector 2, pin 29, or open circuit between Transmission Temperature
Sender and ECM connector 2, pin 25.
• Faulty Transmission Oil Temperature Sender (Bb).
• Faulty ECM.
• Temperature is below --40_C (--40_F).
Tests:
• H5, won’t show “d29” if Transmission Temperature Sender (Bb) is disconnected.
• HC, won’t show an accurate temperature.
Effects:
• Transmission is modified; extreme low temperature is assumed so clutch pack pressures will be low,
resulting in sluggish operation and clutch pedal inching occurs at a higher level. Error may be self-resolved
as voltage reaches normal range, [once the transmission oil temperature warms up, above --30_C (--22_F)].
Recovery:
• If temperature increases but error remains, then cause must be resolved and error must be cleared using
the CDU, HF Menu.

NO Connect the connection and/or
valves unit guard.
wiring.
Is connection (72) and the sensor wiring con-
nected?
YES
Disconnect sensor connection (72).

Using a digital tester, measure the sensor electri-
cal resistance. NO Replace the sensor if interrupted.
With the oil temperature at 20°C (68°F), is the
resistance ∼ 500 Ω?
YES
Lift the engine bonnet and disconnect connection

(69). NO
Is there electrical continuity between connection cause of the open circuit.
(72) (HM) on the sensor and pin (A2) (HM) (trans-
mission side) on connection (69)?
YES
Is there electrical continuity between connection NO

(72) (VN) on the sensor and pin (B6) (VN) on con-
nection (69)?
YES

(85) on the ECM.
Is there electrical continuity between pin (A2) (HM) NO
on connection (69) and pin CN2--25 (HM) on con-
nections (85)?
YES
Is there electrical continuity between pin (B6) (VN)

on connection (69) and pin CN2--29 (VN) on con- NO
nections (85)?
YES
Turn the starter key to the ON position.

Is there a reading of +12V between pin CN2--25 NO Replace the ECM.
(HM) (wiring side) on connections (85) and
ground? (Transmission oil temperature sensor Bb)
YES

short to +12V.
72
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
129
FAULT CODE 51
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 52 – TRANSMISSION TEMPERATURE SENDER (Bb) SHORT CIRCUIT.
Conditions:
• The ECM detects voltage is below 0.34 volts at ECM connector 2, pin 25.
Causes:
• Faulty wiring; circuit shorted to ground between ECM connector 2, pin 25 and Transmission Temperature
Sender, or across sender terminals, or between Transmission Temperature Sender and ECM connector 2,
pin 29.
• Faulty Transmission Temperature Sender (Bb).
• Faulty ECM.
• Transmission oil temperature is above 130_C (266_F).
Tests:
• H5, won’t show “d29” if Transmission Temperature Sender (Bb) is disconnected.
• HC, won’t show an accurate temperature.
Effects:
• Transmission is modified; extreme high temperature is assumed so clutch pack pressures will be low
resulting in sluggish operation and clutch pedal inching occurs at a higher level. Error may be self-resolved
as voltage reaches normal range, [once the transmission oil temperature cools down, below 130_C (266_F)].
Recovery:
• If temperature decreases but error remains, then cause must be resolved and error must be cleared using
the CDU, HF Menu.
Replace the sensor if in short.
Turn the starter key to the OFF position. Disconnect sensor connection (72).
Remove the rear left--hand wheel. Using a digital tester, measure the sensor
NO electrical resistance. NO
Is connection (72) and the temperature
sensor wiring in short? With the oil temperature at 20° C (68° F), is
the resistance ∼ 500 Ω?
YES
YES
of the short circuit. Disconnect the control panel and the con-
NO
Is wire (HM) on sensor connection (72) in
short to ground?
YES
Check the wiring between sensor connec-

tion (72), pin (A2) (HM) on connection (69)
and pin CN2--25 (HM) on connections (85).
YES
Replace the ECM.
(Transmission oil temperature sensor Bb)
72
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
130
FAULT CODE 52
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 53 – 5 VOLTS SENSOR SUPPLY SHORT TO 12 VOLTS.
Conditions:
Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 2, pin 20 and any other 5 volt sensor, [Clutch
Pedal Potentiometer, Power Shuttle FNR lever, Main (C1) Gear and Range (G1) Gear Position Switches.
• Faulty ECM.
Tests:
Effects:
tractor).
• This error may be displayed instead of showing errors for the different individual circuits.
Recovery:

(85) on the ECM. NO Replace the ECM.
Is there a reading of +12V between pin CN2--20
(AB) (wiring side) and ground?
YES

short on pin CN2--20 (AB) to +12V.
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 54 – 5 VOLTS SENSOR SUPPLY SHORT TO GROUND OR OPEN.
Conditions:
Causes:
• Faulty wiring; circuit shorted to ground between ECM connector 2, pin 20 and any other 5 volt sensor, [Clutch
Pedal Potentiometer, Power Shuttle FNR lever, Main (C1) Gear and Range (G1) Gear Position Switches.
• Faulty ECM.
Tests:
Effects:
tractor).
• This error may be displayed instead of showing errors for the different circuits.
Recovery:

Is pin CN2--20 (AB) (wiring side) in short to
ground?
YES
Check the sensors voltage wire (AB) on the wiring:

Shuttle lever, clutch pedal potentiometer, forward
and reverse gear synchroniser position pushbut-
ton, range and gear neutral position sensor push-
buttons and the creeper position sensor pushbut-
ton.
To facilitate this search, use the diagram shown in
Section 55, Chapter 5, page 141.
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 55 – POWER SHUTTLE FNR LEVER (1) FORWARD POSITION SWITCH SHORT
TO 5 OR 12 VOLTS.
Conditions:
Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 2, pin 20 and PS FNR Lever Forward
Position Switch, or short to 5v across switch terminals, or short to 5 or 12v between PS FNR Lever Forward
Position Switch and ECM connector 2, pin 26. Or common 5 volt sensor supply wire from ECM connector
2, pin 20 is shorted to 12v between switch and any other 5 volt sensor.
• Faulty PS FNR Lever Forward Position Switch (1).
• Faulty ECM.
Tests:
• H5, won’t display “d22”.
Effects:
• Transmission will operate normally, except there will be a slight delay whenever the forward position is
selected.
• ECM will determine shuttle position by using the PS FNR Lever Neutral and Reverse Position Switches.
Recovery:

(85) on the ECM. Replace the Shuttle lever if a short
When the Shuttle lever (1) is positioned in forward NO circuit is found.
gear, between pin CN2--20 (AB) and pin CN2--26
(AN) (wiring side), is the reading ∼ 600 Ω?
YES
Replace the ECM.
(Shuttle lever 1)
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
131
FAULT CODE 55
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 56 – POWER SHUTTLE FNR LEVER (1) FORWARD POSITION SWITCH SHORT
TO GROUND OR OPEN CIRCUIT.
Conditions:
Causes:
• Faulty wiring; circuit is shorted to ground or open between ECM connector 2, pin 20 and PS FNR Lever
Forward Position Switch, or across switch terminals, or between PS FNR Lever (1) Forward Position Switch
and ECM connector 2, pin 26. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted
to ground or open between switch and any other 5 volt sensor.
• Faulty PS FNR Lever Forward Position Switch (1).
• Faulty ECM.
Tests:
Effects:
• Transmission will operate normally, except there will be a slight delay whenever the forward position is
selected.
• ECM will determine shuttle position by using the PS FNR Lever (1) Neutral and Reverse Position Switches.
Recovery:

Disconnect the control panel and the con- Is there electrical continuity between
nections (85) on the ECM. NO CN2--20 (AB) on connections (85) and con- NO
Is wire (AN) on pin CN2--26 in short to nection (90) (AB) on the Shuttle lever?
ground? YES
YES
Is there electrical continuity between
Check the wiring between pin CN2--26 CN2--26 (AN) on connections (85) and con- NO
(AN) on connections (85) and connection nection (90) (AN) on the Shuttle lever?
(90) on the Shuttle lever. YES
Replace the Shuttle lever.
YES
Replace the ECM.

the open circuit.
(Shuttle lever 1)
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
132
FAULT CODE 56
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
90
0,5 A (4)
0,5 AN (5)
0,5 AB (6)
0,5 MN (3)
0,5 HV (2)
0,5 B (1)
FAULT CODE 57 – POWER SHUTTLE FNR LEVER (1) REVERSE POSITION SWITCH SHORT
TO 5 OR 12 VOLTS.
Conditions:
Causes:
• Faulty wiring; circuit is shorted to 12 volts between ECM connector 2, pin 20 and PS FNR Lever Reverse
Position Switch, or short to 5v across switch terminals, or short to 5 or 12v between PS FNR Lever Reverse
Position Switch and ECM connector 2, pin 27. Or common 5 volt sensor supply wire from ECM connector
2, pin 20 is shorted to 12v between switch and any other 5 volt sensor.
• Faulty and PS FNR Lever Reverse Position Switch (1).
• Faulty ECM.
Tests:
Effects:
• Transmission will operate normally, except there will be a slight delay whenever the reverse position is
selected.
• ECM will determine shuttle position by using the PS FNR Lever Neutral and Forward Position Switches.
Recovery:

(85) on the ECM.
Replace the Shuttle lever if a short
Move the Shuttle lever to the reverse gear position, NO
circuit is found.
between pin CN2--20 (AB) and pin CN2--27 (A) on
connections (85) (wiring side), is the reading ∼ 600
Ω?
YES
Replace the ECM.
(Shuttle lever 1)
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
133
FAULT CODE 57
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 58 – POWER SHUTTLE FNR LEVER (1) REVERSE POSITION SWITCH SHORT
TO GROUND OR OPEN CIRCUIT.
Conditions:
Causes:
• Faulty wiring; circuit shorted to ground or open between ECM connector 2, pin 20 and PS FNR Lever Reverse
Position Switch, or between switch terminals, or between PS FNR Lever Reverse Position Switch and ECM
connector 2, pin 27. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted to ground
or open between switch and any other 5 volt sensor.
• Faulty PS FNR Lever Reverse Position Switch (1).
• Faulty ECM.
Tests:
Effects:
• Transmission will operate normally, except there will be a slight delay whenever the reverse position is
selected.
• ECM will determine shuttle position by using the PS FNR Lever Neutral and Forward Position Switches.
Recovery:

Disconnect the control panel and the con- Is there electrical continuity between
nections (85) on the ECM. NO CN2--20 (AB) on connections (85) and con- NO
Is wire (A) on pin CN2--27 in short to nection (90) (AB) on the Shuttle lever?
ground? YES
YES
Is there electrical continuity between
Check the wiring between pin CN2--27 (A) CN2--27 (A) on connections (85) and con- NO
on connections (85) and connection (90) nection (90) (AN) on the Shuttle lever?
on the Shuttle lever. YES
Replace the Shuttle lever.
YES
Replace the ECM.

the open circuit.
(Shuttle lever 1)
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
134
FAULT CODE 58
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
90
0,5 A (4)
0,5 AN (5)
0,5 AB (6)
0,5 MN (3)
0,5 HV (2)
0,5 B (1)
FAULT CODE 59 – POWER SHUTTLE FNR LEVER (1) NEUTRAL, FORWARD, & REVERSE
POSITION SWITCHES DISAGREE.
Conditions:
• The ECM detects that two or none of the Power Shuttle FNR Lever Position Switches, (Neutral, Forward,
or Reverse) are activated at the same time.
Causes:
• A particular position switch could be sticking, for example inputs could be indicated for two switches
simultaneously, (both neutral and forward, both neutral and reverse, both forward and reverse, and nothing
from neutral, forward, or reverse).
• Faulty wiring; open circuit between ECM connector 2, pin 18 and Power Shuttle FNR Lever Neutral Position
Switch.
• Faulty Power Shuttle FNR Lever Neutral Switch (1).
• Faulty Power Shuttle FNR Lever Forward Switch (1).
• Faulty Power Shuttle FNR Lever Reverse Switch (1).
• Faulty ECM.
Tests:
• H9, channel 9 and 10 are out of range.
• H5, won’t show “d22” or “d23”.
Effects:
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever. Any voltages
recorded out of range will result in displaying separate error codes.
Recovery:
(Shuttle lever 1)
FAULT CODE 61 – VOLTAGE FROM SYNCHRONIZER HI-LO (FORWARD) POSITION SWITCH

(S) SHORT TO 5 OR 12 VOLTS.

NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. They will flash in a alternating
manner.
Conditions:
1. While the Power Shuttle FNR Lever is in the forward position, voltage at the ECM connector 2, pin 2 is above
4.2 volts.
2. While the Power Shuttle FNR Lever is in the neutral position, voltage at the ECM connector 2, pin 23 is above
4.2 volts.
Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 2, pin 20 and Synchronizer Hi-Lo (Forward)
Position switch, or short to 5v across switch terminals, or short to 5 or 12v between Synchronizer Hi-Lo
(Forward) Position Switch and ECM connector 2, pin 2. Or common 5 volt sensor supply wire from ECM
connector 2, pin 20 is short to 12v between switch and any other 5 volt sensor.
• Faulty Synchronizer Hi-Lo (Forward) Position Switch (S).
• Faulty ECM.
Tests:
• Transmission is limited; only Synchronizer Shuttle (Reverse) Position Switch is available (reverse
movement). Any shuttle into forward will not work. Transmission is neutralized whenever Power Shuttle FNR
is put into forward position. Then ECM will look for detection of Synchronizer Shuttle (Reverse) Position
Switch and move synchronizer to reverse position.
Recovery:

valves unit guard.
Disconnect connection (97*) on pushbutton (HI If in short circuit, replace the push-
NO
and LO) (grey connection). button.
Using a digital tester, measure the electrical resist-
ance on the pushbutton.
YES
Are wires (AB) and (HV) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES YES
Lift the engine bonnet and disconnect connection Check the wiring between pins (A3)
(158). (HV) and (C6) (AB) on connection
NO (158) with pins CN2--2 (HV) and
Are wires (AB) and (HV) still in short?
CN2--20 (AB) on connections (129)
YES
on the ECM.
Check the wiring between pin (A3) (HV) on con- Does the fault persist?
nection (158) or between pin (C6) (AB) on connec-
tion (158) and connection (97*) on pushbutton.
* 97
0,5 AB
0,5 HV
PAGE LEFT BLANK

FAULT CODE 61
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 62 – VOLTAGE FROM SYNCHRONIZER HI-LO (FORWARD) POSITION SWITCH

(S) SHORT TO GROUND OR OPEN CIRCUIT.

manner.
Conditions:
1. While the Power Shuttle FNR Lever is in the forward position, voltage at the ECM connector 2, pin 2 is below
0.7 volts.
2. While the Power Shuttle FNR Lever is in the neutral position, voltage at the ECM connector 2, pin 2 is below
0.7 volts.
Causes:
• Faulty wiring; circuit short to ground or open between ECM connector 2, pin 20 and Synchronizer Hi-Lo
(Forward) Position Switch, or across switch terminals, or between Synchronizer Hi-Lo (Forward) Position
Switch and ECM connector 2, pin 2. Or common 5 volt sensor supply wire from ECM connector 2, pin 20
is short to ground or open between switch and any other 5 volt sensor.
• Faulty ECM.
Tests:
• Transmission is limited; only Synchronizer Shuttle (Reverse) Position Switch is available (reverse
movement). Any shuttle into forward will not work. Transmission is neutralized whenever Power Shuttle FNR
is put into forward position. Then ECM will look for detection of Synchronizer Shuttle (Reverse) Position
Switch and move synchronizer to reverse position.
Recovery:

the open circuit.
solenoid valves unit guard. NO Connect the connection and/or wiring.
Is the wiring and connection (97*) on the
pushbutton connected?
YES
Disconnect connection (97*) on the push-

button.
YES
Raise the engine hood.
Is wire (HV) on connection (97*) in short Disconnect connection (158).
NO Is there electrical continuity between con- NO
to ground?
YES
nection (97*) on pushbutton (HV) and pin
(A3) (HV) on connection (158)?
Check the wiring and eliminate the cause YES
Is there electrical continuity between con-
nection (97*) on pushbutton (AB) and pin NO
(C6) (AB) on connection (158)?
YES
Disconnect the control panel and connec-

CN2--2 (HV) on connections (129) and pin
(A3) (HV) on connection (158)?
YES
Replace the ECM.
* 97
0,5 AB
0,5 HV
PAGE LEFT BLANK

FAULT CODE 62
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 63 – F/R SYNCHRONIZER DID NOT MOVE INTO THE HI-LO (FORWARD)
POSITION.

NOTE: This is the same as the synchronizer not disengaging from reverse.
manner.
NOTE: On the 32x16 transmission, the Shuttle (Reverse) and Hi-Lo (Forward) Synchronizer is located on the
left side of the transmission behind the Power Shuttle Control Valve. The Synchronizer Shuttle (Reverse)
position is toward the front of the tractor. The Synchronizer Hi-Lo (Forward) position is toward the rear of the
tractor.
Conditions:
• During directional change (a shuttle), moving the PS FNR Lever to forward position, the F/R Synchronizer
did not engage the forward position within the time allowed.
Causes:
• Faulty F/R Synchronizer.
• Faulty F/R Synchronizer linkage.
Tests:
• H9, channel 5 is not within allowable range.
Effects:
• Once the error has been cleared, the ECM will attempt to put the F/R Synchronizer into the Hi-Lo (Forward)
position again. This error will be triggered until an attempt to shift the F/R Synchronizer into forward position
has been successful.
Recovery:

valves unit guard.
Replace the HI and LO forward gears synchroniser
position sensor pushbutton.
YES
Replace the HI and LO forward gears synchroniser

solenoid valve.
YES
Check the hydraulic system, the synchroniser unit

and eliminate the fault.
FAULT CODE 64 – F/R SYNCHRONIZER DID NOT MOVE INTO THE SHUTTLE (REVERSE)
POSITION.

NOTE: This is the same as the synchronizer not disengaging from forward.
manner.
NOTE: On the 32x16 transmission, the Shuttle (Reverse) and Hi-Lo (Forward) Synchronizer is located on the
left side of the transmission behind the Power Shuttle Control Valve. The Synchronizer Shuttle (Reverse)
position is toward the front of the tractor. The Synchronizer Hi-Lo (Forward) position is toward the rear of the
tractor.
Conditions:
• During directional change (a shuttle), moving the PS FNR Lever to reverse position, the F/R Synchronizer
did not engage the reverse position within the time allowed.
Causes:
• Faulty Synchronizer Shuttle (Reverse) Position Switch.
• Faulty F/R Synchronizer linkage.
• Tests:
• H9, channel 6 is not within allowable range.
Effects:
• Transmission is disabled but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.
• Once the error has been cleared, the ECM will attempt to put the F/R Synchronizer into the Shuttle (Reverse)
position again. This error will be triggered until an attempt to shift the F/R Synchronizer into reverse position
has been successful.
Recovery:

valves unit guard.
Replace the Shuttle reverse synchroniser position
sensor pushbutton.
YES
Replace the Shuttle synchroniser position solenoid

valve.
YES
Check the hydraulic system, the synchroniser unit

and eliminate the fault.
FAULT CODE 65 – SYNCHRONIZER HI-LO (FORWARD) SOLENOID CIRCUIT SHORT TO

GROUND OR OPEN CIRCUIT OR ECM DRIVER IS OPEN.

manner.
NOTE: On the 32x16 transmission, the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Solenoids are
located on the bottom of the Power Shuttle Control Valve. The Synchronizer Shuttle (Reverse) Solenoid is toward
the rear of the tractor. The Synchronizer Hi-Lo (Forward) Solenoid is toward the front of the tractor. Both
solenoids are 12v, on/off.
Conditions:
1. While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position, the
Synchronizer Hi-Lo (Forward) Solenoid has a short to ground or open circuit.
2. While the tractor is started and the Power Shuttle FNR Lever is in the neutral position, the Synchronizer Hi-Lo
(Forward) Solenoid has a short to ground or open circuit.
Causes:
• Faulty wiring; circuit is short to ground or open between the ECM connector 1, pin 16 and solenoid coil
terminal, or across the solenoid coil terminals or between solenoid coil terminal and ECM connector 1, pin
4.
• Faulty Synchronizer Hi-Lo (Forward) Solenoid Coil.
• Faulty ECM; internal ECM Driver is open or short to ground.
Tests:
• H9, channel 12 is not within range.
• Transmission is limited; only Synchronizer Shuttle (Reverse) Solenoid is available (reverse movement). Any
shuttle into forward will not work. Transmission is neutralized whenever Power Shuttle FNR is put into
forward position. Then ECM will look for detection of Synchronizer Shuttle (Reverse) Solenoid and move
synchronizer to reverse position.
Recovery:

the open circuit.
solenoid valves unit guard. NO Connect connection.
Is connection (67) on the HI and LO for-
ward gear synchroniser position control
solenoid valve connected?
YES
Disconnect connection (67) on the sole-

noid valve.
Using a digital tester, measure the electri- NO Replace the solenoid valve if interrupted.
YES

Is wire (GN) on pin CN1--16 on connec- Is there electrical continuity between pin
NO CN1--16 (GN) on connections (129) and NO
tions (129) or wire (GR) on pin CN1--4 in
short to ground? connection (67) on the solenoid valve?
YES YES
Check the wiring between connection (67) Is there electrical continuity between pin
CN1--4 (GR) on connections (129) and con- NO
on the solenoid valve, pins (B2) (GN) and
(C1) (GR) on connection (158) and pins nection (67) on the solenoid valve?
CN1--16 (GN) and CN1--4 (GR) on con- YES
nections (129).
Eliminate the cause of the short to ground. Replace the ECM.
PAGE LEFT BLANK

FAULT CODE 65
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 66 – SYNCHRONIZER SHUTTLE (REVERSE) SOLENOID CIRCUIT SHORT TO

GROUND OR OPEN CIRCUIT OR ECM DRIVER IS OPEN.

manner.
Conditions:
1. While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position, the
Synchronizer Shuttle (Reverse) Solenoid has a short to ground or open circuit.
2. While the tractor is started and the Power Shuttle FNR Lever is in the neutral position, the Synchronizer
Shuttle (Reverse) Solenoid has a short to ground or open circuit.
Causes:
• Faulty wiring; circuit is short to ground or open between the ECM connector 1, pin 17 and the Synchronizer
Shuttle (Reverse) Solenoid Coil terminal, or across the solenoid coil terminals, or between the Synchronizer
Shuttle (Reverse) Solenoid Coil terminal and ECM connector 1, pin 3.
• Faulty ECM, internal ECM driver is open or short to ground.
Tests:
• Transmission is limited; only Synchronizer Hi-Lo (Forward) Solenoid is available (forward movement). Any
shuttle into reverse will not work. Transmission is neutralized whenever Power Shuttle FNR is put into
reverse position. Then ECM will look for detection of Synchronizer Hi-Lo (Forward) Solenoid and move
Recovery:

the open circuit.
Is connection (65) on the solenoid valve of NO Connect connection.
the Shuttle reverse synchroniser position
control connected?
YES
Disconnect connection (65) on the sole-

noid valve.
Using a digital tester, measure the electri- NO Replace the solenoid valve if interrupted.
YES

nections (129) on the ECM. Is there electrical continuity between pin
Is wire (SN) on pin CN1--17 on connec- NO CN1--17 (SN) on connections (129) and NO
tions (129) or Wire (SG) on pin CN1--3 in connection (65) on the solenoid valve?
short to ground? YES
YES
Check the wiring between connection (65) CN1--3 (GS) on connections (129) and con- NO
on the solenoid valve, pins (B4) (SN) and nection (65) on the solenoid valve?
(C4) (GS) on connection (158) and pins YES
CN1--17 (SN) and CN1--3 (GS) on con-
nections (129). Replace the ECM.
PAGE LEFT BLANK

FAULT CODE 66
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 67 – SYNCHRONIZER HI-LO (FORWARD) SOLENOID OR ECM DRIVER IS

SHORT TO 12 VOLTS.

manner.
Conditions:
• While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position, the
Synchronizer Hi-Lo (Forward) Solenoid becomes energized by a short circuit to 12 volts.
Causes:
• Faulty wiring; circuit shorted to 12 volts between the ECM connector 1, pin 16 and the Synchronizer Hi-Lo
(Forward) Solenoid Coil terminal, or across the solenoid coil terminals, or between the Synchronizer Hi-Lo
(Forward) Solenoid Coil terminal and ECM connector 1, pin 4.
• Faulty ECM, internal ECM Driver is shorted to
Tests:
Effects:
• Transmission is limited; Synchronizer Hi-Lo (Forward) Solenoid remains energized, therefore keeping F/R
Synchronizer Piston in forward position. Only forward engagement is operational. Hi-Lo speed engagement
is operational. Any shuttle into reverse will not work.
Recovery:

(GN) on connections (129) and ground?
YES
Check the wiring between pin CN1--16 (GN) on

connections (129), pin (B2) (GN) on connection
(158) and connection (67) on the solenoid valve.
Eliminate the cause of the short circuit to +12V.
PAGE LEFT BLANK

FAULT CODE 67
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 68 – SYNCHRONIZER SHUTTLE (REVERSE) SOLENOID OR ECM DRIVER IS

SHORT TO 12 VOLTS.

manner.
Conditions:
• While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position, the
Synchronizer Shuttle (Reverse) Solenoid become energized by a short circuit to 12 volts.
Causes:
• Faulty wiring; circuit is shorted to 12 volts between the ECM connector 1, pin 17 and the Synchronizer Shuttle
(Reverse) Solenoid Coil terminal, or across the solenoid coil terminal, or between the Synchronizer Shuttle
(Reverse) Solenoid Coil terminal and ECM connector 1, pin 3.
• Faulty Synchronizer Shuttle (Reverse) Solenoid Coil.
• Faulty ECM; internal ECM Driver is short to 12 volts.
Tests:
Effects:
• Transmission is limited; Synchronizer Shuttle (Reverse) Solenoid remains energized, therefore keeping F/R
Synchronizer Piston in reverse position. Only reverse engagement is operational. Hi-Lo speed engagement
is applicable with reverse. Any shuttle into forward will not work.
Recovery:

(SN) on connections (129) and ground?
YES
Check the wiring between pin CN1--17 (SN) on

connections (129), pin (B4) (SN) on connection
(158) and connection (65) on the solenoid valve.
Eliminate the cause of the short circuit to +12V.
PAGE LEFT BLANK

FAULT CODE 68
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)
158
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 69 – WHEEL SPEED SENSOR (Aa) SHORT TO GROUND OR OPEN.
Conditions:
• The ECM detects voltage at ECM connector 2, pin 36 is below 1.8 volts.
Causes:
• Faulty wiring; circuit shorted to ground or open between ECM connector 2, pin 36 and Wheel Speed Sensor
(Aa), or across sensor terminals.
• Faulty Wheel Speed Sensor (Aa).
• Faulty ECM.
Tests:
• H9, channel 19, is not within range.
Effects:
• Transmission is modified; Power Shuttle FNR Lever may not work properly. No acceleration feedback
monitored during automatic take-off (ATO).
Recovery:

Lift the engine bonnet and disconnect
connection (69). NO NO
Is pin CN2--36 (HR) on connections (85)
Is pin (B3) (HB) (wiring side) in short to
(wiring side) in short to ground?
ground?
YES
YES
Check the wiring between pin CN2--36 (HB)
Remove the rear left--hand wheel.
on connections (85) and pin (B3) (HB) on
Check the wiring between connection (76)
connection (69).
on the sensor and pin (B3) (HB) on con-
nection (69).
Replace the ECM.
(Speed sensor wiring Aa)
76
0,5 VN
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
135
FAULT CODE 69
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 71 – F/R SYNCHRONIZER UNABLE TO CHANGE POSITION

DURING START UP.

manner.
NOTE: On the 32x16 transmission, the ECM will attempt to change position of the F/R Synchronizer each time
the key switch is turned to the “ON” or to the “START” position. The F/R Synchronizer is in the Hi-Lo (forward)
position when it is shifted toward rear of tractor. The F/R Synchronizer is in the Shuttle (reverse position when
it is shifted toward front of tractor.
Conditions:
• The ECM is unable to change the position of the F/R Synchronizer within 30 seconds after the tractor has
been started.
Causes:
• Faulty F/R Synchronizer Shift Piston in Power Shuttle Control Valve.
• Faulty F/R Synchronizer shift rail or fork.
• Faulty Synchronizer Hi-Lo (Forward) or Shuttle (Reverse) Position Switches (T and S).
• Faulty Temperature Sensor, (Transmission oil temperature too cold.)
• Faulty ECM.
Tests:
• H9, channel 5 or 6 are not within range.
• H5 doesn’t display “d27” or “d28”.
Effects:
• Transmission is disabled; if oil temperature is OK, (above 0_C/32_F), this error could correct itself after the
F/R Synchronizer has been successfully shifted into a different position.
Recovery:

Replace the two synchroniser position sensor
pushbuttons (HI -- LO and Shuttle).
YES
Start the engine and accelerate to 1000 rpm.

Disconnect the synchroniser solenoid valves
(Shuttle/HI--LO) and the two relative synchroniser
position sensor pushbuttons.
Using an external battery, alternately power--up
the two Shuttle and HI -- LO solenoid valves.
Using a digital tester, check that the synchroniser
position sensor pushbuttons are pressed alter-
nately.
(560 Ω pushbutton pressed, 2.7 kΩ pushbutton re-
leased).
YES
Check the synchroniser unit and the relative hy-

draulic system to eliminate the cause of the fault.
FAULT CODE 72 – F/R SYNCHRONIZER DISENGAGED FROM POSITION.

manner.
NOTE: On the 32x16 transmission, the ECM will attempt to change position of the F/R Synchronizer each time
the key switch is turned to the “ON” or to the “START” position. The F/R Synchronizer is in the Hi-Lo (forward)
position when it is shifted toward rear of tractor. The F/R Synchronizer is in the Shuttle (reverse position when
it is shifted toward front of tractor.
Conditions:
• The ECM detects a change in the position of the F/R Synchronizer without a command from the PS FNR
Lever.
Causes:
• Faulty F/R Synchronizer Shift Piston in Power Shuttle Control Valve.
• Faulty F/R Synchronizer shift rail or fork.
• Faulty Synchronizer Hi-Lo (Forward) or Shuttle (Reverse) Position Switches (T and S).
• Faulty ECM.
Tests:
• H9, channel 5 or 6 are not within range.
• H5 doesn’t display “d27” or “d28”.
Effects:
Transmission will only operate in the previous shuttle direction.
Recovery:

Replace the two synchroniser position sensor
pushbuttons (HI -- LO and Shuttle).
YES

Disconnect the synchroniser solenoid valves
(Shuttle/HI--LO) and the two relative synchroniser
position sensor pushbuttons.
Using an external battery, alternately power--up
the two Shuttle and HI -- LO solenoid valves.
Using a digital tester, check that the two synchro-
niser position sensor pushbuttons are pressed al-
ternately.
(560 Ω pushbutton pressed, 2.7 kΩ pushbutton re-
leased).
YES
Check the synchroniser unit and the relative hy-

draulic system to eliminate the cause of the fault.
FAULT CODE 73 – ECM (2) SUPPLY VOLTAGE (12VF) IS TOO HIGH.
Conditions:
• When tractor is on, ECM detects that the voltage at ECM connector 2, pin 34 or ECM connector 2, pin 10
is above 18 volts for longer that 0.3 seconds.
Causes:
• Faulty Battery.
• Overcharged Battery.
Tests:
• H9, channel 3, is above 762.
Effects:
• Transmission is critically disabled, but can be re-enabled by cycling the Ignition Switch, (shutting off the
tractor). Dump solenoid stays energized. Indicator lights will not illuminate when key switch is in the “ON”
or “Start” position. ECM stops sending diagnostic pulses to the sensors, switches, or solenoids. This error
will automatically clear when voltage dropped below 16 volts
Recovery:

Start the engine and accelerate to 1200 rpm. Check the recharging system and re-
NO place the alternator if the voltage is
Using a digital tester, measure the battery voltage.
Is the voltage ∼ 14V? much higher than +14 V.
YES
Replace the ECM (1).
(ECM 1)
FAULT CODE 74 – ECM SUPPLY VOLTAGE (12VF) IS TOO LOW.
Conditions:
• When tractor is on, ECM detects that the voltage at ECM connector 2, pin 34 or ECM connector 2, pin 10
is below 9 volts for longer that 0.3 seconds.
Causes:
• Faulty Battery.
• Undercharged Battery.
Tests:
• H9, channel 3, is below 428.
Effects:
tractor). Dump solenoid stays energized. Indicator lights will not illuminate when key switch is in the “ON”
or “Start” position. ECM stops sending diagnostic pulses to the sensors, switches, or solenoids. This error
will automatically clear when voltage raises above 9 volts.
Recovery:

Remove the left--hand panel located under the
dashboard. NO Replace the fuse.
Fuse F16 (5A) (Section 55, Chapter 5, page 2)
Does it work?
YES

(85) on the ECM. Check the wiring between connec-
Turn the starter key to the ON position. NO tions (85) and the fusebox and elimi-
Between pin CN2--10 (MN) and pin CN2--34 (MN) nate the cause of the open circuit.
on connections (85) and ground, is the reading
+12V?
YES
Replace the ECM.
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
FAULT CODE 76 – ECM TRIPLICATE READ ERROR IN THE NON-VOLATILE MEMORY (NVM).
Conditions:
• It is impossible to recall any data from the NVM because all three stored copies are different.
Causes:
• Damaged Electrically Erasable Programmable Read Only Memory (EEPROM) micro-chip.
• Faulty ECM (2).
Tests:
Effects:
• Transmission is modified; ECM will re-set to default settings. The tractor performance may be affected in
the area where setting have been changed to improve characteristics, (H2, H3, H6, H7, & HE). The ECM
will try to store any self learned or collected data when tractor is shut down.
Recovery:
(ECM 1)
FAULT CODE 77 – INTERNAL ECM SUPPLY VOLTAGE (8V) IS TOO HIGH.

NOTE: This pin is not used externally as an actual output. This is a internal print board circuit error.
Conditions:
• The ECM detects that the voltage at ECM connector 2, pin 35 is above 8 volts.
Causes:
• Faulty ECM (2).
• ECM connector 2, pin 35 is/was shorted by an external 12 volt source.
• Internal circuit short to 12 volts.
Tests:
Effects:
tractor).
Recovery:
(ECM 1)
FAULT CODE 78 – INTERNAL ECM SUPPLY VOLTAGE (8V) IS TOO LOW.

NOTE: This pin is not used externally as an actual output. This is a internal print board circuit error.
Conditions:
• The ECM detects that the voltage at ECM connector 2, pin 35 is below 8 volts.
Causes:
• Faulty ECM (2).
• ECM connector 2, pin 35 is/was shorted to an external ground or 5 volt source.
• Internal circuit short to ground.
Tests:
Effects:
tractor).
Recovery:
(ECM 1)
FAULT CODE 81 – TRANSMISSION HYDRAULIC OIL PRESSURE SWITCH SHORT TO

GROUND OR OPEN.
Conditions:
• The ECM detects a short to ground or open between Transmission Pressure Switch and ECM connector2,
pin 31.
Causes:
• Faulty wiring; circuit shorted to ground or open between ECM connector 2, pin 20 and Transmission Pressure
Switch, or between the switch terminals, or between the Transmission Pressure Switch and ECM
connector2, pin 31. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted to ground
or open between switch and any other 5 volt sensor.
• Faulty Transmission Pressure Switch.
• Faulty ECM.
Tests:
Effects:
• Transmission is modified; transmission oil pressure information is not available. During the first 30 seconds
of start up, the pressure switch reaches a pressure above 11 bar (160 psi), a signal is sent from the ECM
to the dump solenoid, allowing the clutch packs to engage. If this doesn’t happen within 30 seconds the error
is registered. If the error is present and oil temperature is above 0_(32_F) the transmission is still operational.
Recovery:

NO Connect the connections.
valves unit guard.
Are the pressure switch connections connected?
YES
Disconnect the pressure switch and the dump so-

lenoid valve connections. NO Replace the pressure switch.
Using a digital tester, check: is the pressure switch
normally closed?
YES
YES
Start the engine.
Check the hydraulic system.
Using a digital tester, check: does the pressure NO NO
Is the oil pressure ∼ 16 bar (232 psi)?
switch open?
YES
Check the hydraulic system.

Is there electrical continuity between wire (AB) on NO
the pressure switch connection and pin (C6) (AB) cause of the open circuit.
on connection (69)?
YES
Is there electrical continuity between wire (SN) on

the pressure switch connection and pin (B4) (SN) NO
on connection (69)?
YES

(85) on the ECM.
Is there electrical continuity between pin CN2--31 NO
(SN) on connections (85) and pin (B4) (SN) on con-
nection (69)?
YES
Is there electrical continuity between pin CN2--20

(AB) on connections (85) and pin (C6) (AB) on con- NO
nection (69)?
YES
Replace the ECM.

ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
136
FAULT CODE 81
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
FAULT CODE 82 – TRANSMISSION HYDRAULIC OIL PRESSURE SWITCH SHORT

TO 5 OR 12 VOLTS.
Conditions:
• The ECM detects a short to 5 or 12 volts between Transmission Pressure Switch and ECM connector2, pin
31.
Causes:
• Faulty wiring; circuit short to 12 volts between ECM connector 2, pin 20 and Transmission Pressure Switch,
or short to 5v across switch terminals, or short to 5 or 12v between the Transmission Pressure switch and
ECM connector2, pin 31. Or common 5 volt sensor supply wire from ECM connector 2, pin 20 is shorted to
12v between switch and any other 5 volt sensor.
• Faulty Transmission Pressure Switch.
• Faulty ECM.
Tests:
Effects:
• Transmission is modified; transmission oil pressure information is not available. During the first 30 seconds
of start up, the pressure switch reaches a pressure above 11 bar (160 psi), a signal is sent from the ECM
to the dump solenoid, allowing the clutch packs to engage. If this doesn’t happen within 30 seconds the error
is registered. If the error is present and oil temperature is above 0_(32_F) the transmission is still operational.
Recovery:

valves unit guard. NO Replace pressure switch.
Disconnect the pressure switch connections.
Are wires (AB) and (SN) in short circuit?
YES
Check the wiring between the pressure switch con-

nections, pin (C6) (AB) and (B4) (SN) on connec-
tion (69) and pins CN2--20 (AB) and CN2--31 (SN)
on connections (85) on the ECM.
ECM PIN REFERENCE
PIN 1 PIN 1
CN1 CN2
137
FAULT CODE 82
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)
1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)
69
1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)
POWER SHUTTLE (8 + 8 and 16 + 16) ELECTRONIC CONTROL UNIT INPUT/OUTPUT

WIRING DIAGRAM
1 Starter switch. 1a: starter function -- 1b: gear function.

2 Starter relay.
3 Shuttle control lever. 3a: on engine starting circuit -- 3b: on power supply control unit circuit.
4 Clutch pedal switch for engine starting circuit.
5 Clutch pedal switch for power supply control unit circuit.
6 Transmission oil pressure sensor indicator light.
8 Transmission alarm indicator light.
9 Clutch A (forward gears) solenoid valve.
10 Clutch B (forward gears) solenoid valve (reverse gears).
13 Dump solenoid valve (hydraulic neutral safety).
14 Parking brake ON output signal, for acoustic alarm.
15 Shuttle lever output signal (to 4WD control unit) if reverse gear is selected.
16 Speed sensor amplified signal to instrument panel.
17 Bodywork ground.
18 Sensors ground.
19 Power ground.
20 Connection for Troubleshooting unit 294084.
21 Pushbutton Y.
22 Pushbutton B.
23 HMENU selection pushbutton.
24 Troubleshooting unit 294084.
25 Speed sensor.
26 Engine revs sensor (from alternator).
27 Parking brake ON switch.
28 Range position sensor switch (G1).
29 Transmission oil pressure for control unit activation.
30 Speed shift position sensor switch (C1).
33 To fuse 15.
34 Driving seat safety switch.
35 Transmission oil temperature sensor.
38 Shuttle lever in reverse gears selection position.
39 Shuttle lever in forward gears selection position.
40 Clutch pedal potentiometer signal.
41 Sensors power supply (+5V).
42 Emergency cable for ”limp home” after electrics breakdown.
43 Battery.
POWER SHUTTLE ELECTRONIC CONTROL UNIT INPUT/OUTPUT WIRING DIAGRAM (8 + 8 and 16 + 16)
2 FUSE 16 (5A)
1a
3a 4 5
3b
FUSE 14 (5A)
6
FUSE 7 (10A)
41
FUSE 9 (10A)
40
FUSE 15 (5A)
8
FUSE 7 (10A)
1b 39
38 9
43
10
NTC 1140 a 0o -- 330 a 40o

35
34
42
33
9
13
30
14
10
29
SW--3
CN2--31
15
28 SW--3 CN2--31
27
16
24
26
680
23
25
22 21 19 18 17
20
MPD2821A
SECTION 23 -- DRIVE LINES -- CHAPTER 1 1
SECTION 23 -- DRIVE LINES
Chapter 1 -- Drive Lines
CONTENTS
23 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description, operation and hydraulic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
23 101 26 Transmission shafts and guard, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8
23 101 40 Drive gear housing assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
23 202 50 Drive gear housing assembly, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
23 101 42 Drive gear housing assembly removed, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . 11
23 202 52 Drive gear housing assembly removed, Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . 13
MAIN SPECIFICATIONS
Reduction ratio of drive gear device (on all models) . . . . . . . . . . . 43/28X28/39 = 1:1.1
2 SECTION 23 -- DRIVE LINES -- CHAPTER 1
TORQUE SETTINGS
C1 -- 88 Nm (65 ft. lbs)
27836
Tightening torque
PART Thread
Nm lfb.lb
Transmission shaft central support retaining bolt (C1) . . . . . . . . . . M 12 x 1.5 88 65
TOOLS

cannot be carried out without the ESSENTIAL tools
marked with an (X).
List of specific tools required for the various op-

erations described in this section.
X 294098 Drive shaft seal key.

X 294049 Key for Ø 50 mm (1.9685 in.) piston.
X 294050 Key for Ø 35 mm (1.3780 in.) piston.
27827
2
Tool to make for drive gear unit removal.
(Stamp no. 50161 on the tool -- Measurement in mm)
Construct in Fe 42C material.
27828
3
Tool to make for drive gear shaft removal.
(Stamp no. 50141 on the tool -- Measurement in mm)
Construct in C40 material. Pin mm 3 x 20 (0.1181 to 0.7874 in.).
1 2 3 4 5 6 7 8 9 10 11 12 13
27832
14
10 13
15
16
17
18
27833
4
Sectional view of drive gear with mechanical coupling
1. Driven shaft. 10. Driving gear.

2. Dust ring. 11. Thrust washer.
3. Seal. 12. Circlip.
4. Circlip. 13. Coupling sleeve.
5. Bearing. 14. Transmission oil drainage plug.
6. Circlip. 15. Control pad.
7. Circlip. 16. Seal.
8. Thrust washer. 17. External control lever.
9. Bearing. 18. Lever return spring (17).
NOTE: On installation, apply sealing compound to the surfaces X (see Section 27, Chapter 1).
20032191
5
Mechanical 4WD Engagement / Disengagement Idler Controls
1. Tie-rod 12. Pin, roll

2. Handle grip 13. Engagement control fork
3. Pin, roll 14. Lever
4. Screw, M6 x 14 15. Bushing
5. Seat/Slot/Spherical bushing 16. Special screw spring
6. Bushing 17. Washer, 14 x 25
7. Washer, Lock, M6 18. Pin, split (cotter), 2 x 18
8. Nut, CL 8, M6 x 1 19. Spring
9. Slide block engagement relay lever 20. Ring, locking, D=14
10. Lever, 4WD coupling inner lever 21. Washer, 10 x 21
11. O ring, 2.62 x 15.88 22. Bushing
The drive gear housing is mounted below the rear the two units.
transmission gearbox and is driven by the transmis- Drive gear engagement and disengagement by
sion shaft via gear unit (10, fig. 4). means of the mechanical 4WD lever on the floor to
Drive is then transmitted from the shaft (1) to the front the left of the seat.
axle by means of the transmission shaft that connects
MECHANICAL 4WD TROUBLESHOOTING
4WD will not engage or Lever (10) seizing up in 4WD drop Remove drop box and clean lever
disengages shortly thereafter. box. (10).
Any part of engage/disengage Break loose, disassemble parts,

linkage damaged/seized up. clean any seized area, remove
corrosion with emery cloth, upon
assembly lubricate all mating
surfaces with grease.
Cotter pin (18) missing allowing

the bushing lever to come out and
hang up on moving parts.
Check moving parts affected,

replace worn/damaged parts,
insert cotter pin.
Op. 23 101 26
TRANSMISSION SHAFTS AND GUARD
WARNING
To remove, proceed as follows:
27801
1. Unscrew the front, central and rear retaining bolts
and remove the transmission shaft guard (1). 6
2. Extract the rear circlip and unscrew the sleeve (1)

back on the splined shaft.
3. Unscrew the central support bolts and extract the

transmission shaft.
4. To re--fit the transmission shaft and guard, pro-

ceed as follows:
WARNING
7
-- Fit and secure the transmission shaft in position.
-- Fit and secure the guard.

Op. 23 101 40 -- 23 202 50
DRIVE GEAR HOUSING ASSEMBLY
WARNING

shafts and guard, only removal (see page 10).
25628
2. Remove the drainage plug and collect the oil in a
suitable. 8
3. Detach the drive gear engagement control lever
(1).
50030468
9
4. Unscrew the eight drive gear housing retaining

bolts (1) on the transmission gearbox.
25982
10
5. Remove the drive gear housing (1) from the
transmission gearbox.
6. To re--fit the drive gear housing, proceed as fol-
lows.
WARNING

page 2.
-- Carefully clean the contact surfaces. 25983
-- Apply the sealing compound (approx. 2 mm -- 11

0.787 in. -- in thickness), as shown in Section 27,
Chapter 1.
-- Fit the drive gear housing on the transmission
gearbox.
-- Connect the drive gear engagement control lever.
-- Replace the transmission oil drainage plug.
shafts and guard, only installation (see page 10).
-- Refill the rear transmission gearbox (for products
and quantities, see Section 00, page 6).
Op. 23 101 42
REMOVED
WARNING
Proceed as follows.

2. Carry out operation 23 101 40 Drive gear housing

assembly, only removal (see page 11). 25984
3. Remove the dust ring (1) and seal (2). 12

4. Remove the circlips and ball bearings (1) from the
seatings.
25985
13
5. Remove the circlip (5) and washer (4), extract the
pin (3) and remove: the external lever (6), the in-
ternal lever (2) and the coupling pad (1).
1
2
6
3
4
27834 5
14
6. Extract the coupling sleeve (1), remove the circlip

(3) and remove: the washer (4), the gear unit (5) 1
and the shaft (2).
7. To refit the drive gear housing, proceed as fol- 2
lows.
WARNING 3
4
-- Insert the shaft in the housing, then assemble the
gear unit, washer and circlip. 27835 5
-- Fit the internal lever, the external lever, the cou-
15
pling pad, securing in position by means of the
washer and relative circlip.
-- Fit the bearing and relative circlips.
-- Using tool 294098, fit the seal and dust ring (use
the spacer to fit the dust ring).
-- Carry out operation 23 101 40 Drive gear housing
assembly, only installation (see page 11).
25989
16
Op. 23 202 52
REMOVED
WARNING
Proceed as follows.

2. Carry out operation 23 202 50 Drive gear housing
assembly, only removal (see page 11).
3. Remove the dust ring (1) and seal (2).
25984
17
4. Remove the circlips and ball bearings (1) from the
seatings.
25985
18
5. Remove the pin (1) fitted on the opposite end of
the shaft and slide off the oil delivery union.
25986
19
6. Using tool 50141 (see fig. 3) and an extracting

tool applied to the end of the shaft, remove the
gears, the bearing, the 4--WD coupling unit and
the oil delivery manifold.
7. Using a hydraulic press and tool 50161 (see
fig. 2), compress the spring, manipulating the
washer, extract the retaining ring and remove the
spring.
Move the end of the piston (mobile coupling 16,
fig.NO TAG) to remove it from the housing.
25988
X-
20
8. To refit the drive gear housing, proceed as fol-
lows.
WARNING
-- Check all parts and replace if worn.

-- Check the seals and the metal seal segments, re-
placing if necessary.
-- Lubricate all parts.
25989
NOTE: The seals (13 and 15, fig. NO TAG) must be 21

inserted in their respective housings as quickly as
possible in order to avoid deformation, using (respec-
tively) tools 294049 and 294050.
-- Insert the piston in the seating.

-- Using a press and tool 50161 fit the spring, wash-
er and retaining ring.
-- Fit the shaft, the oil delivery manifold, the 4--WD
coupling assembly and the bearing in the drive
gear housing.
-- Fit the oil delivery union and secure the shaft by
means of the circlip.
-- Fit the bearing and relative circlips.
-- Using tool 294098, fit the seal and dust ring (use
the spacer to fit the dust ring)).
-- Carry out operation 23 202 50 Drive gear housing
assembly, only installation (see page 11).
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 1
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION
Chapter 1 -- Front Axle Mechanical Transmission

CONTENTS
25 000 Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cross--sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25 100 30 Front Axle, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
25 108 30 Front Epicyclic Final Drive, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
25 108 46 Steering Knuckle Bearing Pins, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
25 100 38 Wheel Hubs and Steering Knuckle Pins and Bearings, Removal--Replacement--Installation 22
25 100 38 Bevel Drive and Front Axle Differential Axle Housing, Disassembly--Assembly . . . . . . . . 25
25 102 20 Front Axle Bevel Drive, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Bevel Drive Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
25 102 24 Front Axle Differential, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
25 102 27 Front Axle Differential with LIM--Slip Unit, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
44 511 80 Leading Drive Wheels Toe-in Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MAIN DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steering, load bearing structure,

pivoting at centre
Bevel drive -- differential
Pinion--crown gear ratio 30 Km/h (18.6 mph):
-- model TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/42 = 1:4.66
-- models TN 65, TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . . . . 8/30 = 1:3.75
Backlash between bevel drive teeth:

-- models TN 55, TN 65, TN 70 and TN 75 . . . . . . . . . . . . . . . . . mm 0.15 to 0.20
(in.) 0.0059 to 0.0079)
Ratio between front wheel revs and rear wheel bevel drive revs
30 km/h (18.6 mph):
-- model TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.402
-- models TN 65, TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . . . . 1.378
2 SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1
MAIN DATA
(continued)
Thickness of bevel pinion position adjustment spacer rings (11, fig. 28) . . . . . . . . . . . . . mm 2.5 -- 2.6 -- 2.7 -- 2.8 -- 2.9 -- 3.0 -- 3.1 -- 3.2
-- 3.3 -- 3.4 -- 3.5 -- 3.6 -- 3.7
(in.) (0.0984 -- 0.1024 -- 0.1063 -- 0.1102 --
0.1142 -- 0.1181 -- 0.1220 -- 0.1260 -- 0.1299
-- 0.1339 -- 0.1378 -- 0.1417 -- 0.1457)
Thickness of pinion bearing adjustment spacer rings (12) . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.5 -- 2.55 -- 2.6 -- 2.65 -- 2.7 -- 2.75 -- 2.8 --
2.85 -- 2.9 -- 2.95 -- 3.00 -- 3.05 -- 3.1 -- 3.15
-- 3.2 -- 3.25 -- 3.3 -- 3.35 -- 3.4 -- 3.45 -- 3.5
-- 3.55 -- 3.6 -- 3.65 -- 3.7 -- 3.75 -- 3.8 --
3.85 -- 3.9 -- 3.95 -- 4..00 -- 4.05 -- 4.1 -- 4.15
-- 4.2 -- 4.25 -- 4.3 -- 4.35 -- 4.4 -- 4.45 -- 4.5
-- 4.55 -- 4.6 -- 4.65 -- 4.7 -- 4.75 -- 4.8
(in.) (0.0984 -- 0.1004 -- 0.1024 -- 0.1043 --
0.1063 -- 0.1083 -- 0.1102 -- 0.1122 -- 0.1142
-- 0.1161 -- 0.1181 -- 0.1201 -- 0.1220 --
0.1240 -- 0.1260 -- 0.1280 -- 0.1299 -- 0.1319
-- 0.1339 -- 0.1358 -- 0.1378 -- 0.1398 --
0.1417 -- 0.1437 -- 0.1457 -- 0.1476 -- 0.1496
-- 0.1516 -- 0.1535 -- 0.1555 -- 0.1575 --
0.1594 -- 0.1614 -- 0.1634 -- 0.1654 -- 0.1673
-- 0.1693 -- 0.1713 -- 0.1732 -- 0.1752 --
0.1772 -- 0.1791 -- 0.1811 -- 0.1831 -- 0.1850
-- 0.1870 -- 0.1890)
Thickness of crown wheel position adjustment spacer (4, fig. 28) . . . . . . . . mm 0.9 -- 1 -- 1.1 -- 1.2 -- 1.3 -- 1.4 -- 1.5 -- 1.6 --
1.7 -- 1.8 -- 1.9 -- 2
(in.) (0.0354 -- 0.0393 -- 0.0433 -- 0.0473 --
0.0512 -- 0.0551 -- 0.0591 -- 0.0630 --
0.0670 -- 0.0709 -- 0.0748 -- 0.0787)
Clearance between sides of planet and side pinion teeth . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.15
(in.) (0.0059)
Thickness of planet pinion thrust washers . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.470 to 1.530
(in.) (0.0579 to 0.060)
Thickness of side gear thrust washers (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2.0
(in.) (0.0591 -- 0.0630 -- 0.0670 -- 0.0709 --
0.0748 -- 0.0787)
Diameter of cross pin (14) for planet pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 21.939 to 21.960
(in.) (0.8637 to 0.8646)
Side pinion cross pin bore diameter (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 22.040 to 22.061
(in.) (0.8677 to 0.8685)
Clearance between cross pin and bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.080 to 0.122
(in.) (0.0031 to 0.0048)
Axle shafts and steering knuckles
Diameter of outer axle shafts (7, fig. 28) in correspondence with bushes (8) . . . . . . . . . . mm 44.975 to 45.000
(in.) (1.7707 to 1.7717)
Inside diameter of installed bushes (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 45.100 to 45.175 (1)
(in.) (1.7756 to 1.7785)
Clearance between axle shafts and bushes .................................... mm 0.100 to 0.200
(in.) (0.0039 to 0.0079)
Interference fit between bushes and respective bores . . . . . . . . . . . . . . . . . mm 0.064 to 0.129
(in.) (0.0025 to 0.0051)
Thickness of steering knuckle bearing adjuster plates (10) . . . . . . . . . . . . . . . . . . . . . . . . mm 0.10 -- 0.15 -- 0.20 -- 0.25 -- 0.30
(in.) (0.0039 -- 0.0059 -- 0.0079 -- 0.0098 --
0.0118)
Epicyclic final drives
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 : (12 + 60) = 1 : 6
Thickness of driven gear shims (9, fig. 28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.77 to 0.83
(in.) (0.0303 to 0.0327)
Axle pivot
Axle clearance on pivot between body and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.3 to 1.1
(in.) (0.0118 to 0.0433)
Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2
(in.) (0.0787)
Diameter axle pivot front pin (3, fig. 29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 52.652 to 52.671
(in.) (2.073 to 2.074)
MAIN DATA
(continued)
Installed front bush internal diameter (1, fig. 29) . . . . . . . . . . . . . . mm 52.720 to 52.790 (1)
(in.) (2.0756 to 2.078)
Clearance between pin (3) and bush (1) . . . . . . . . . . . . . . . . . . . . . mm 0.049 to 0.138
(in.) (0.0019 to 0.0054)
Outside diameter of rear bush (6) installed in the bevel pinion
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 99.020 to 99.050
(in.) (3.898 to 3.900)
Inside diameter of rear bush (5) installed in the axle pivot support mm 99.146 to 99.221 (1)
(in.) (3.903 to 3.906)
Assembly clearance between the two bushes . . . . . . . . . . . . . . . . mm 0.096 to 0.201
(in.) (0.0038 to 0.0079)
Thickness of the front (2) and rear (4) front axle thrust washers . mm 4.95 to 5.00
(in.) (0.195 to 0.197)
(1) Measurement to be obtained without reaming
TORQUE SETTINGS
Torque setting
PART Thread
Nm ft-lbs
Front axle
Nut for axle--shaft retaining bolt (C1) . . . . . . . . . . . . . . . . . . . . . . . . M 12X1.25 77 to 93 56 -- 68

Ring gear to differential cage retaining bolt (C2) . . . . . . . . . . . . . . . M 12X1.25 119 to 144 87 -- 106
Differential locknut safety tab retaining bolt (C3) . . . . . . . . . . . . . . M 10X1.25 36 to 51 26 -- 37

Final drive assembly support to axle casing retaining bolt (C4) . . 87 -- 106
M 12 X 1.25 119 to 144
Bevel pinion shaft locknut (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 35X1.5 294 216

Pipe unions on power control hydraulic cylinders (C6) . . . . . . . . . -- 44 32
Pipe unions on manifolds for control hydraulic cylinders (C7) . . . -- 25 to 27 18 -- 19
Tie rod ball joint locknuts (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 142 104
Tie rod ball joint retaining bolt (C9) . . . . . . . . . . . . . . . . . . . . . . . . . . -- 206 to 235 151 -- 173
Ball joint locknut on tie rod (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 196 144

Steering knuckle pin retaining bolt (C11) . . . . . . . . . . . . . . . . . . . . . M 10X1.25 64 47
Rim to hub retaining bolt (C12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18X1.5 170 to 206 125 -- 151
Epicyclic final drive case retaining bolt (C13) . . . . . . . . . . . . . . . . . M 10X1.25 55 to 67 41 -- 49
Wheel hub bearing locknut (C14) . . . . . . . . . . . . . . . . . . . . . . . . . . . M 70 X 2 392 290

Differential lock retaining bolt (C1 page 5) . . . . . . . . . . . . . . . . . . . . M 10X1.25 60 to 70 44 -- 51
Differential lock control hydraulic fitting (C2) . . . . . . . . . . . . . . . . . . -- 73 53
Differential lock control hydraulic fitting (C3) . . . . . . . . . . . . . . . . . . -- 44 32
Brake control cylinder retaining bolt (C4) . . . . . . . . . . . . . . . . . . . . . M 10X1.25 66 to 73 48 -- 53

Differential cage support cap bolt (C5) . . . . . . . . . . . . . . . . . . . . . . . M 12X1.25 119 to 144 87 -- 106
Upper pivot bearing locknut (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 20 14
Upper pivot pin locknut (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 290 to 320 213 -- 236
Bearing support retaining bolt (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . M 12X1.5 98 72

Front pivot support retaining bolt (C9) . . . . . . . . . . . . . . . . . . . . . . . -- 510 to 617 376 -- 455
Lower pivot pin retaining bolt (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . -- 136 to 165 100 -- 121
Rear pivot bearing support retaining bolt (C11) . . . . . . . . . . . . . . . . M 24 X 2 390 to 490 287 -- 361
Rear pivot pin retaining bolt (C12) . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 412 to 451 303 -- 332
Planet support to cover retaining bolt (C13) . . . . . . . . . . . . . . . . . . M 12X1.25 119 to 144 87 -- 106
Rim and cover to hub retaining bolt (C14) . . . . . . . . . . . . . . . . . . . . M 18X1.5 170 to 206 125 -- 151
TORQUE SETTINGS
(216 ft-lbs) (32 ft-lbs)
C5 -- 294 Nm C6 -- 44 Nm
(87 to 106 ft-lbs)
C4 -- 119 to 144 Nm
C7 -- 25 to 27 Nm
(18 to 19 ft-lbs)
25509
C2 -- 119 to 144 Nm C3 -- 36 to 51 Nm C1 -- 77 to 93 Nm
(87 to 106 ft-lbs) (26 to 37 ft-lbs) (56 to 68 ft-lbs)
(151 to 173 ft-lbs) (144 ft-lbs) (41 to 49 ft-lbs)

C9 --206 to 235 Nm C10 -- 196 Nm C13 -- 55 to 67 Nm
C11 -- 64 Nm (47 ft-lbs)
C8 -- 142 Nm (104 ft-lbs) C12 -- 170 to 206 Nm
(125 to 151 ft-lbs)
25510 C4 -- 66 to 73 Nm
(48 to 53 ft-lbs)
1
C3 --44 Nm (32 ft-lbs)
C2 --73Nm
(53
ft-lbs)
25512
C4 -- 66 to 73 Nm
25511 C1 -- 60 to 70 Nm (44 to 51
(48 to 53 ft-lbs)
ft-lbs)
(87 to 106 ft-lbs) C6 -- 20 Nm (14 ft-lbs) (72 ft-lbs)
C5 -- 119 to 144 Nm C8 -- 98 Nm
C7 -- 290 to 320 Nm
(213 to 236 ft-lbs)
25513 C10 --136to165 Nm

(100 to 121 ft-lbs)
C9 -- 510 to 617 Nm (376 to 455 ft-lbs)
(125 to 151 ft-lbs)
C14 -- 170 to 206 Nm (287 to 361 ft-lbs) (303 to 332 ft-lbs)
C11 -- 390 to 490 Nm C12 -- 412 to 451 Nm
(101 ft-lbs)
C13 -- 137 Nm
25515 25514
2
TOOLS
X 293782 Front bevel drive pinion retaining

Warning -- The operations described in this section wrench.
cated by an (X). 293400 Universal gauge for positioning of front
To work safely and efficiently and obtain the best re- bevel drive pinion.
X 293544 Wrench for front differential case bear-
ing threaded adjustment ring.
cluded in this manual. 294150 Wheel hub seal splining tool.
List of specific tools required for the various opera- X 295030 Wrench for front axle wheel hub bear-
tions described in this section. ing retaining nut (TN55 may need
modification to tool, see fig. 25).
293460 Front axle overhaul stand.
50169 Pins (M10 x 1.25) for front axle and
291517 Front differential unit removal--installa- cover.
tion hook.
50165 Pins (M 16 x 1,25) for front axle wheels
293743 Front axle differential casing overhaul disassembly/assembly.
support.
X 293857 Front axle pivot pin removal tool.
X 293878 Wrench for front bevel drive pinion ring X 292161 Front axle pivot bearing outer ring re-
nut. moval tool.
X 293391 Pinion bearing adjustment tool (with X 292220 Tool for measurement of rolling drag
50118 earlier version 50118 needs torque of front axle bearings.
made see fig. 24).
292870 Universal kit for testing oil pressure for
X 293510 Universal gauge for pinion bearing ad- front axle differential lock engagement
justment. (with 293874 and 291318).
Tool to be made for adjustment of bevel drive pin-

ion; to be used in conjunction with earlier version
of tool 293391
[mark tool No. 50118 -- measurement in mm (ins)].
(.393)
(1.377)
(1.88)
26135
24
mm (.590 ins)
mm (4.05 ins)
3mm (.120 ins)
25
(TN55 only) Modification to make earlier version of tool 295030 [Measurement in mm (ins)]
(.196)
(.393)
(3.936)
(.787)
27892
26
Tool to be made for front axle wheel disassembly--assembly.

[Mark tool with No. 50165 -- Measurement in mm (ins)]
(.196)
(.393)
(3.936)
(.590)
10
27893
27
Tool to be made for front axle gear unit cover disassembly--assembly.
[Mark tool with No 50169 -- Measurement in mm (ins)]
7 8 9
10
26128
X
28
Cross--sectional view of front axle
H4 = 95 mm (3.740 ins). Nominal distance between 9. Shims for driven gears of epicyclic final gear.
crown wheel axis and greater diameter of the pinion.
10. Steering knuckle adjustment plates.
1. Thickness of side gears thrust washers.
2. Side gears. 11. Thickness of bevel pinion position adjustment
3. Bevel gear. spacer.
4. Side pinions. 12. Thickness of bevel pinion bearing adjustment spacer.
5. Differential casing. 13. Seal.
6. Ring gear bearings adjustment nut.
7. Axle shaft. 14. Cross pin for side pinions.
8. Axle shaft bush (7). 15. Crown wheel bearing adjustment nut.
NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 29.
1 2 3 4 5 6
26131
29
Cross--sectional view of front axle pivot
1. Axle pivot front bush. 5. Rear bush installed on axle support.

2. Front thrust washer. 6. Rear bush installed on bevel drive--differential sup-
3. Axle pivot front pin. port.
4. Rear thrust washer.

TN 55, TN 65, TN 70 and TN 75 tractors are provided mitted to lateral epicyclic final drive units (installed on
with a centrally pivoting front axle with pivot and drive the wheel hubs) through universal joints which do not
shaft coaxial to the tractor longitudinal axis. The drive require any maintenance.
shaft is not fitted with universal joints.
The differential has two planet pinions; drive is trans-
OP. 25 100 30
FRONT AXLE ASSEMBLY
DANGER
equipment.
Make sure that the load is supported by means of
suitable slings and hooks. Make sure that no--one is
standing in the vicinity of the load to be lifted.
Proceed as follows:
NOTE: The front axle assembly can be removed from

the tractor either with or without previously removing
the drive shaft. The description below refers to
removal of the front axle with the drive shaft installed
on the tractor. For removal of the drive shaft refer to
section 23.
1. Unscrew the bolts (1) and remove the front mud-

guard supports (2). 1 2
25575
30
2. Attach a nylon sling to the front ballasting (1), ex-

tract the locking pin; lift the ballasting and remove 1
to a safe position.
25577
31
3. Unscrew the bolts (1) and remove the drive shaft
guard (2).
1 2
25576
32
4. Remove the circlip (2), slide the sleeve (1) to-
wards the rear and free the drive shaft from the
1 2
front axle.
25584
33
5. Attach the front axle to a hoist using two nylon
slings.
25580
34
6. Raise the tractor and position a fixed stand under
the engine sump.
25581
35
7. Unscrew the front differential lock control unions

(1) and remove the hose (2). 1 2
8. Unscrew the rigid pipes from the power steering
cylinder and disconnect the two hoses.
25579
36
9. Unscrew the retaining bolts and remove the front
wheels.
25582
37
10. Allow the slings on the axle to take the strain and
remove the front axle rear support retaining bolts 1
(1).
25585
38
11. Remove the front axle front support retaining
bolts (1).
1
25586
39
12. Using the hoist and the two nylon slings, detach
the front axle.
13. To refit the front axle on the tractor, proceed as

follows.
WARNING
-- Position the axle, tighten the front and rear sup- 25583
ports to the relative support. 40

-- Reconnect the differential lock pipe and the pow-
er steering pipes.
-- Fit the front wheels.
-- Using the hoist, raise the front part of the tractor.

-- Extract the fixed stand.
-- Remove the nylon slings from the axle.
-- Connect the drive shaft and position the guard.
-- Refit the two front mudguards.
-- Attach a nylon sling to the front ballasting, fit and
secure in position with the lock rod.
-- Re--connect the battery negative lead.
on page 3.
Op. 25 108 30
FRONT EPICYCLIC FINAL DRIVE
Disassembly -- Assembly
WARNING
Front epicyclic final drive removal and installation can

be carried out with the axle detached and positioned
on the stand 293460, or with the axle fitted on the
tractor. If the operation is performed with the axle
fitted on the tractor, a support stand must be
positioned under the engine sump. 25587
NOTE: TN65, 70, 75 art work shown unless 41

specified.
Proceed as follows:
1. Turn the epicyclic final drive to position the filler/

drain plug at its lowest point and drain the oil. 1
25589
42
2. Unscrew the planetary carrier (1) retaining bolts.
Screw in the two pins 50169 (2) and, using an ex- 1 2
tractor fitted on the oil drainage plug, detach the
planetary carrier (1) and remove.
25594
43
3. Remove the lock nut (1) on the wheel hub bear-
ings using wrench 295030 (2). 1
NOTE: For TN55, see tools, 295030.
25597
44
25598
45
4. Remove the wheel hub (1) together with the final
drive fixed gear (2). Recover all disassembled 1 2
parts.
25599
46
DISASSEMBLY, REBUILD, AND ASSEMBLY

OF THE PLANETARY GEARS
NOTE: When disassembling planetary carrier

assembly, keep all parts for each shaft together to
facilitate reassembling.
TN 55
Disassembly
1. From outside of the planetary cover (1), remove 2
1
the three cap screws (2) holding the planetary
gear support.
20030469
47
2. From inside planetary cover (1), remove
planetary gear support (2). 1
20030470
48
3. Remove planetary gear (1), the two thrust
washers (2), and the twenty two needle roller
bearings (3). 3
Repeat this procedure for remaining planetary gears.
2 1
20030471
49
4. If necessary to replace planetary pins (1), remove
pins (1) from the inside out, (see arrows). 1
NOTE: When installing planetary pins, to prevent
scoring, dip pins into liquid nitrogen before assembly.
Inspection and Repair

5. Clean all components in a suitable solvent. Allow
parts to dry.
6. Inspect outer tracks inside hub housings.
Replace as necessary.
7. Inspect planetary gears, needle roller bearings, 20030472
and planetary pins, and replace in sets if worn or
damaged. 50
Assembly
8. Assembly of the planetary carrier follows the
disassembly procedures in reverse, observing
the following.
9. Ensure twenty two needle roller bearings are in
each planetary gear.
10. Torque the three cap head screws holding the
planetary gear support to 130 N⋅m (95 ft lbs).
TN 65, 70, AND 75
Disassembly
2
1. To remove planetary gear (1), remove planetary
pin (2) from the inside out, (see arrow). 3
2. Remove the planetary gear (1), the two thrust
washers (3), and the nineteen needle roller
bearings inside the gear. Repeat this procedure
for the remaining planetary gears.
Inspection and Repair
1
3. Clean all components in a suitable solvent. Allow
parts to dry. 20030473
4. Inspect outer tracks inside hub housings.
Replace as necessary. 51
5. Inspect planetary gears, needle roller bearings,
and planetary pins, and replace in sets if worn or
damaged.
Assembly
6. Assembly of the planetary carrier follows the
disassembly procedures in reverse, observing
the following.
NOTE: When installing planetary pins, to prevent

scoring, dip pins into liquid nitrogen before assembly.
7. Ensure nineteen needle roller bearings are in

each planetary gear.
To refit the front epicyclic final drive, proceed as

follows.
WARNING

earlier in this section.
-- Assemble the wheel hub and the epicyclic final
drive fixed gear.
-- Progressively tighten the ring nut, using the
torque wrench and wrench 295030 (1) to obtain
a torque value of 392 Nm (290 ft-lbs); at the same
time, rotate the wheel hub to ensure that the bear- 52
ings are correctly seated.
Measure the rolling resistance (Rt) of the wheel
hub using the relative torque wrench, or a torque
meter and cord positioned on the base of the
wheel disk flange.
Loosen the ring nut by half a turn and measure
the rolling resistance (R) as described previously.
The difference between the two measurements is
the rolling torque value of the wheel hub bearings
(Rc):
Rc = Rt -- R = 5.9 to 14.7 Nm (4.3 to 11 ft-lbs) or,
if measured with a torque meter.
Rc = Rt -- R = 7.5 to 18.75 kg (5.5 to 41.3 lb.)
(model TN 55)
Rc = Rt -- R = 4.8 to 12 kg (10.6 to 26.5 lb.) (mod-
els TN 65, TN 70 and TN 75)
If the value is less than a 5.9 Nm (4.3 ft-lbs) or,
with the torque meter, 7.5 kg (16.5 lb.) (for model
TN 55) or 4.8 kg (10.6 lb.) (for models TN 65,
TN 70 and TN 75) replace the relevant parts and
repeat the test.
-- Progressively tighten the ring nut, using the
torque wrench and wrench 295030 (1) to obtain
a torque value of 392 Nm (290 ft-lbs); at the same
time, rotate the wheel hub to ensure that the bear-
ings are correctly seated.
-- Carefully secure the ring nut.
-- Before reassembling the epicyclic final drive cas-
ing, carefully clean and degrease the mating sur-
faces, then apply sealing compound (approx. 2
mm; 0.0787 in.) along the marked line shown on
page 30.
-- Assemble the epicyclic final drive casing, com-
plete with gears.
-- Fill up the front epicyclic final drive (for recom-
mended products and quantities see page 6, sec-
tion 00).
-- Fit the track rods.
WHEEL HUB SEAL

Replacement
WARNING
Proceed as follows:
1. Carry out operation 25 108 30 Front epicyclic final
drive, only removal (see page 19).
2. Remove the hub casing (1) and the spacer. 53
3. Remove the worn seal, carefully clean the seat
and position the new seal (1) on the seat fitting.
NOTE: The external surface on the seal (1), indicated

by the arrow, does not require lubrication.
54
4. Fit tool 294150 (2) on the hub and fit, by a few
mm, the seal (3) using a striker (1).
55
5. Fully fit the seal in position using the ring nut and
wrench 295030 (1).
6. To refit the wheel hub parts, proceed as follows.
WARNING
-- Remove tool 294150 from the hub.

-- Carry out operation 25 108 30 Front epicyclic final
drive, only installation (see page 20).
56
OP. 25 108 46 or 25 108 47

STEERING KNUCKLE PINS AND
BEARINGS
Replacement
WARNING
If steering knuckle pivot pins present problems during

disassembly operations, proceed as follows.
1. Remove the grease nipples and the steering

knuckle pin retaining bolts.
2. Fit the bolts (1) of tool 293857.
3. Fit the plate (2) of the tool and fix it to the three
bolts with nuts (5).
24596
4. Fit the central tie bolt (4), screwing it fully into the
grease nipple bore on the pin (6).
5. Screw in the nut (3) to drive the pin out of its bore. 57
WHEEL HUBS AND STEERING KNUCKLE

PINS AND BEARINGS
Removal--Replacement--Installation
(Op. 25 108 38, Op. 25 108 46 or 25 108 47)
WARNING
gloves and shoes.
Wheel hub removal can only be carried out after hav-

ing disassembled the front epicyclic final drive.
6. Place the stub axle in a nylon sling (1), remove
the pin and grease fittings (2) retaining bolts (3). 1 2 3
25564
58
7. Fit the three bolts (1) of tool 293857. Fit the plate
(2) of the tool and secure with the three bolts (1) 2
and nuts (5). Fit the center tie bolt (4), screwing 4
it fully into the grease nipple bore on the pin (6).
Screw in the nut (3) to drive the pin out of the bore.
Repeat the operation on both pins and recover 6
the adjustment shims. 5
3
1
25565
59
8. Detach the wheel hub and steering knuckle (1)
and separate the two units. 1
25566
60
9. Using extractor tool 292161 (1) remove the
steering knuckle bearings.
1
10. Re--install the steering knuckle bearings using a
suitable striker.
WARNING
24599
61
11. To refit the steering knuckle and wheel hub,
proceed as follows.
WARNING
-- Refer to the cross section illustrations earlier in
this chapter for positioning of various parts.
earlier in this chapter.
-- Assemble the steering knuckle on the axle body
and adjust the bearings as follows.
12. Smear AMBRA GR 9 grease on the outer races

of the bearings and fit the upper cover, without the 1
adjustment plate, but with tool 292220 (1).
Tighten the retaining bolts to a torque value of 64
Nm (47 ft-lbs).
13. Fit the lower cover without adjustment plate,
lubricate the three retaining bolts with engine oil.
14. Gradually tighten the lower cover bolts in
sequence, while simultaneously rotating the
casing to allow the excess grease to escape.
25715
62
15. Using a torque wrench and tool 292220 (1), check
that the torque required to rotate the casing is 3.9 1
to 5.9 Nm (3.5 -- 5.3 ins-lbs) without considering
the peak starting value. If not, adjust by way of the
lower cover bolts.
16. Measure the gap (H) created between the lower
cover and the casing in correspondence with the
three bolts.
17. Calculate the average of the three values
measured. The total thickness of the adjustment
shims (10, page 9) to be fitted under the lower
cover will be the average obtained, rounded down 25716
to the next 0.05 mm (.002 ins).
18. Partially unscrew the lower cover bolts, insert the 63
shims (10, page 9) and tighten the bolts to a
torque value of 64 Nm (47 ft-lbs).
19. After having rotated the casing a few times to
allow the components to bed down, check that
the torque necessary to rotate the casing is 3.9 to
9.8 Nm (34 -- 86 ins-lbs), without considering the
initial peak torque.
20. If the torque value measured is greater than the
prescribed value, increase the thickness of the
shims; if the measured value is less than the
prescribed value, reduce the thickness of the
shims.
21. Remove tool 292220 and tighten the retaining
bolts to a torque value of 64 Nm (47 ft-lbs).
22. Assemble the grease fittings in the upper and
64
lower covers and grease the assembly.
23. Refit the front epicyclic final drive.
OP. 25 100 38
BEVEL DRIVE AND FRONT AXLE
DIFFERENTIAL AXLE HOUSING
WARNING
NOTE: Front axle overhaul operations must be

25587
carried out on stand No. 293460.
65
1. Unscrew the plug (1) and drain the oil from the
axle casing.
1
25588
66
2. Unscrew the plug (1) on the left--hand epicyclic fi-
nal drive housing; repeat the same operation on 1
the right--hand housing.
25589
67
3. Remove the front axle rear support (1); remove
the front support and washer. 1
25590
68
4. Loosen the two track rod lock nuts (1).

1
25591
69
5. Using an extractor, extract the pins from the seats
on the stub axle housing, recovering the track
rods.
24080
70
6. Remove the circlips (2) from the cylinder rod pivot
pins, unscrew the cylinder (1) pins retaining bolts,
extract the pins and remove the two cylinders.
1 2
Remove the four pins, washers, spacers and cyl-
inders, complete with pipes.
25593
71
7. Unscrew the left--hand side gear cover (1) retain-
ing bolts. Tighten two pins 50169 (2) and, using 2
1
an extracting tool screwed into the oil drainage
plug hole, remove the cover (1).
25594
72
8. Remove the lock nut (1) on the wheel hub bear-
ings using wrench 295030 (2). 1
NOTE: For TN55, see tools 295030.
25597
73
2
25598
. 74
9. Remove the wheel hub (1) together with the epi-
cyclic crown (2). Recover all disassembled parts.
1 2
25599
75
10. Unscrew the three stub axle lower pin retaining
bolts (1). Recover the lower pivot pin and the rela-
tive adjusting spacers.
1
25600
76
11. Unscrew the three mudguard support (2) retain-

ing bolts (1).
1 2
25601
77
12. Extract the upper pivot pin (1) and remove the
stub axle (2). Recover all disassembled parts.
2
1
25602
78
13. Unscrew the axle shaft (1) retaining bolt (2).
1 2
25603
79
14. Using a crowbar, remove the axle shaft (1,
fig. 79).
15. To disassemble the right hand side gear unit, ob-

serve the order of operations used for the disas-
sembly of the left hand side gear unit, from opera-
tion No. 7 to operation No. 17.
25604
80
16. Unscrew the bracket (1), loosen the union (3) and
remove the differential lock control rigid pipe (2). 1 2 3
25605
81
17. Unscrew the two bevel drive--differential support
retaining bolts from the axle casing, screw on the
1 2 3
two pins 50169 (1). Remove the remaining bolts
and the bevel drive--differential support, attach a
chain (2) and put the hoist under strain. Remove
the bevel drive--differential support (3) from the
axle casing.
25606
82
OP. 25 102 20
FRONT AXLE BEVEL DRIVE OVERHAUL 1 2
1. Fit tool 293743 (1) in the vice on a work bench,
lock the bevel drive--differential support in the tool
and remove the chain.
3
2. Unscrew the bolt (2) and recover the ring nut lock-
ing plate (3). Remove the differential lock control
internal pipe.
25607
83
3. Unscrew the bevel drive--differential support cap
(1) retaining bolts (2) and remove. 2
1
25612
84
4. Remove the bevel drive--differential (2) housing
(1). 1 2
25613
85
5. Remove the circlip (1) from the splined shaft (2).
1 2
25614
86
6. Straighten the staking on the splined shaft lock
nut (1). 1
25615
87
7. Unscrew the nut, using wrench 293878 (1) hold-
ing the bevel pinion shaft in position with wrench
1
293782.
25616
88
8. Remove the splined shaft stop ball (1).
1
25617
89
9. Acting on the rear part, extract the bevel pinion
shaft (1) and recover the spacer, adjusting shims
1
and the bearing.
25618
90
10. Using a screwdriver, detach and remove the dust

seal, seal (1) and rear bearing. 1
11. To assemble the front axle, proceed as follows:
WARNING
-- Refer to the cross section illustrations earlier in

this chapter for the positioning of various parts.
-- Respect the tightening torques prescribed earlier
in this chapter. 25619
-- Carry out the adjustments described in this chap- 91

ter.
-- Fit the rear bearing, seal, dust seal, adjusting
shims, spacer and bevel pinion shaft, complete
with front bearing.
-- Position the sto ball, tighten and secure the bevel
drive nut, then position the circlip.
-- Assemble the bevel drive--differential unit, sup-
port caps and tighten the relative screws.
-- Reconnect the bevel drive--differential support to
the front axle casing and fit the differential lock ex-
ternal pipe.
-- Fit the axle shaft and screw.
-- Fit the stub axle, the adjusting shims, lower and
upper pivot pins, mudguard support and screws.
-- Fit the wheel hub, side gear crown and ring nut
and tighten to the prescribed torque, whilst rotat-
ing the hub to settle the bearings.
-- Fit the circlips, drive gear and side gear cover.
-- Fit the pins, washers, spacers and steering con-
trol cylinder.
-- Fit the track rod, front and rear supports and the
oil drainage plug.
BEVEL DRIVE ADJUSTMENTS

Adjusting the preloading on the bevel drive
shaft bearings
WARNING
gloves and shoes.
Proceed as follows.
7
1. Clamp tool 293391 (1) in a vice. Slide tool spacer
50118 (2) onto the tool (see tools 293391). Slide 6
a bearing (3) from the bevel assembly onto the
tool. Slide the spacer (4) from the bevel assembly
5
onto the tool. Slide the remaining bearing (5) from
the bevel assembly onto the tool. Slide the top
cone (6) from the tool onto the tool threads.
Tighten the tool nut (7) to 1.2 Nm (10 in. lbs).
92
2. Using a micrometer, measure distance (H1) be-
tween the upper surface of the top cone (6) and
the top of the threaded pin (7) of tool 293391 (1). 7
93
3. Disassemble the parts mentioned above, lubri-
cate the bearings with engine oil and then reas-
semble the parts, (excluding only the bearing
bevel assembly spacer (4, fig. 96), into the bevel 6
drive--differential housing, complete with outer 2
bearing races.
4. On tool 29339, torque the nut (7, fig. 96) to 1.2
Nm (10 in. lbs), while turning the tool to ensure
that the bearings are seated correctly.
5. Using micrometer, measure distance (H2)
between the upper surface of the top cone (6) and
the top of the threaded pin of tool 293391.
6. The thickness of the adjustment shim (12) re-
quired is given by: 94
S = H2 -- H1 + 0.05 mm
If necessary, round this value up to the nearest

0.05 mm.
NOTE: On completing the adjustment, do not remove

the adjustment tool 293391 from the bevel drive--dif-
ferential housing: leave in place for adjustment of the
drive pinion position.

Determining the thickness of the drive pinion
position adjustment shim
Proceed as follows.
1. Install tool 293400 (1) in the bevel drive--differen- 1 2
tial housing, complete with outer bearing rings,
differential bearings adjustment shim, circlip and
differential housing caps.
2. Screw the cones (2) of tool 293400 (1) in or out
in order to position the micrometer shaft in the
direction of the inner bearing ring and eliminate
end float between the cones and the outer rings
of the differential bearings.
3. Adjust the micrometer so that the shaft is in con-
tact with the inner bearing ring and measure the
distance (H3) obtained. 25594
4. Determine the correct distance (H5) between the 95

differential axis and the large diameter base of the
pinion:
H5 = H4 ± C
where:
H4 = 95 mm
Nominal distance between the crown wheel axis
and the large diameter base of the pinion.
C = correction value stamped on pinion preceded
by a + or -- sign (no mark on the pinion, C equals
0), to be added to or subtracted from the nominal
distance (H4) according to the sign.
5. The thickness of the adjustment shim (11, page
9) will be given by:
S = H3 -- H5
where:
H3 = the distance measured using the microme-
ter;
H5 = corrected nominal distance between the
differential axis and the large diameter base of the
pinion.
Example.
-- Distance measured using micrometer H5 = 98
mm.
-- Nominal distance between ring gear axis and lar-
ge diameter base of H4 = 95 mm.
-- Correction value C = + 0.2 mm.
-- Corrected nominal distance H5 = 95 + 0.2 = 95.2
mm
-- Thickness of adjustment shim
S = 98 -- 95.2 = 2.8 mm.
-- Correction value C = -- 0.2 mm.
-- Corrected nominal distance H5 = 95 -- 0.2 = 94.8
mm.
S = 98 -- 94.8 = 3.2 mm.
-- Correction value C = 0 mm.
-- Corrected nominal distance H5 = H4 = 95 mm.
S = 98 -- 95 = 3 mm.
6. Remove tools 293391 and 293400 from bevel

drive housing.
7. Install the drive pinion (3) complete with: inner
bearing rings, spacer (1), adjustment shims of the
1 2 3
previously determined thickness, ball joint and
relative bush. Lubricate all parts before installing.
25588
96
8. Position the wrench 294080 (2) for the pinion nut

and the wrench 294079 (1) for the splined pinion.
1 2
9. Using the torque wrench on wrench 294079 (1),
whilst holding the pinion in position by means of
wrench 294080 (2), tighten the pinion nut to a
torque value of 382 Nm (281 ft-lbs) while simulta-
neously rotating the pinion shaft to ensure that
the bearings are seated correctly.
10. With torque wrench 293952 (2) fitted on wrench
2934079 (1), check that the pinion rolling torque,
without oil seal and relative dust seal, is 0.5 to 1
Nm (4.4 -- 8.8 ins-lbs).
If the rolling torque is less than the prescribed 25595
value, fit a thinner adjustment shim, if the torque
97
is greater than the prescribed value, fit a thicker
adjustment shim.
11. Unscrew the nut and fit the oil seal and the rela-
tive dust seal ring. Tighten the nut to a torque
value of 294 Nm (216 ft-lbs) while simultaneously
rotating the pinion shaft to ensure that the bear-
ings are seated correctly.
12. With torque wrench 293952 (2) fitted on wrench

294079 (1) check that the pinion rolling torque, 1 2
with the oil seal and relative dust seal, is ≤ 0.50
Nm (4.4 ins-lbs).
Finally, carefully stake the nut.
25596
98

Adjustment of the differential bearings and 1 2 3
checking the backlash between the pinion and
ring gear.
Proceed as follows.
1. Install the differential assembly (2), complete with
bearings, adjustment shim (1) and relative circlip
in the bevel drive--differential housing.
25578
99
2. Install the differential support caps and the ring
nut (2), tighten the relative bolts (1) to a torque 1 2
value of 59 Nm (43 ft-lbs), then loosen and re--
tighten to a torque of 20 Nm (14 ft-lbs).
25597
100
3. With the bearings perfectly lubricated, rotate the
ring gear and, at the same time, tighten the ring 1
nut using wrench 293544 (1) to a torque value of
39 to 59 Nm (28 -- 43 ft-lbs) to take up the axial
play between the components.
4. Measure the backlash between pinion and ring
gear, using a 1/100 dial gauge perpendicular to
the outer edge of a tooth on the ring gear (1).
25598
101
5. Repeat the measurement in a further two posi-
tions 120° apart and compare the average of the 1
three values (Gm) with the prescribed normal
backlash: 0.15 to 0.20 mm (.006 to .008 ins,
average valve .007 ins) average value 0.18 mm.
If the measured backlash exceeds the prescribed
value, fit a thinner adjustment shim.
The thickness of the adjustment shim to be fitted
in the bevel drive--differential housing is given by:
25599
102
S = Sp -- {(Gm -- 0.18 ) x 1.35}

where:
Sp = thickness of test shim installed in the bevel
drive--differential housing;
Gm = average backlash measured between the sides
of the teeth of the bevel drive.
If the backlash measured is less than the prescribed
value, it will be necessary to fit a thicker adjustment
shim, the value being given by:
S = Sp + {(0.18 -- Gm) x 1.35}
(S = Sp + [0.007 ins -- Gm] x .053 ins)
where:
Sp = thickness of test shim installed in the bevel
drive--differential housing;
Gm = average backlash measured between the sides
of the teeth of the bevel drive
6. Install a shim of the calculated thickness and with
a 1/100 scale dial gauge positioned perpendicu-
lar to the outside edge of one of the ring gear
teeth, check that the backlash between the pinion
and the ring gear is within the prescribed toler-
ance limits 0.15 to 0.20 mm (.006 -- .008 ins)
7. Using wrench 293544 (1) turn the adjustment ring
nut and check using torque wrench 293952 (2),
1
that the rolling resistance torque of the differential
and pinion bearings, as measured in the same
conditions used to check only the pinion, is:
A2 = A1 + 1 to 1.5 Nm (8.8 to 13 ins-lbs)
where:
A2 = pinion/differential rolling resistance torque;
A1 = rolling resistance torque of pinion only as
previously measured;
0.1 to 1.5 Nm (.8 to 13 ins-lbs) = rolling resistan-
ce torque of differential only measured at the end 25598
of the pinion, using wrench 294079 (1) and torque 103

wrench 293952 (2).
1 2
25596
104
8. Tighten the cap bolts (1) to a torque value of 119
to 144 Nm (87 -- 106 ft-lbs). 2
1
9. Fit the safety plate, screwing the adjustment ring
nut in or out, to reach the nearest notch.
10. Attach the bevel drive--differential to the axle cas-
ing after having carefully cleaned and degreased
the mating surfaces and apply sealing compound
(approx. 2 mm [.078 ins]) along the marked line
shown in the figure below.
25597
105
Adhesive application diagram for assembly of
bevel drive unit and epicyclic final drive unit.
The types of adhesive to use are listed on page 1,
section 00.
24595
106
OP. 25 102 24
FRONT AXLE DIFFERENTIAL
Overhaul
In case of differential assembly overhaul it is neces-

sary to adjust the backlash between the teeth of the
planet pinions and the side gears.
Proceed as follows.
1. Thoroughly clean the components of the differen-

tial to remove any traces of oil that would other-
wise prevent accurate backlash measurement.
2. Install the two side gears without thrust washers.
3. Fit the planet pinions complete with thrust wash-

ers and pins and screw down the pin retaining
bolts by a few turns to hold the pins in place.
4. Position a dial gauge on the differential housing.
5. Move the left hand side gear to bring it into full

contact with the planet pinion and then push it up
24597
against the differential housing, reading the end-
float (Gs) on the dial gauge. 107
6. Repeat the above operations to measure the

endfloat on the right hand side gear (Gd).
The side gear endfloat will be 0.25 mm (0.0098

in.).
Therefore the shims to be inserted in the differen-

tial housing are given by:
Ss = Gs -- 0.25 mm (0.0098 in.) for the left--hand

side gear;
Sd = Gd -- 0.25 mm (0.0098 in.) for the right--hand

side gear.
7. Install shims as near as possible to the calculated
value and, using a dial gauge and following the
previously described procedure, check that the 24598
endfloat of the left and right hand side gears is
approximately 0.25 mm (0.0098 in.). 108
LIM--SLIP SELF--LOCKING DIFFERENTIAL

LOCK
Operation
The differential with limited slip locking (LIM -- SLIP)
is of the two planet gear--type, provided with two mul-
ti--disk clutch assemblies fitted between the side
gears and the differential casing.
This differential lock device is totally automatic. It
does not require any type of manual operation and
significantly reduces (but does not completely elimi-
nate) wheel slipping.
The difference in revolutions, between the side gears
and the differential casing when a wheel begins to slip
as a result of grip loss, is impeded by clutch assem-
blies that are compressed by axial thrusts from the 27966
bevel drive torque transmitted to the side gears by
means of the teeth on the two planet.
These torque values may be different, according to
the nature of the ground and the route followed by the 109
tractor, and may vary in intensity thereby proportion-
ally determining the axial stress on the clutches, al-
lowing the side gears to mesh with the differential
casing which, in turn, permits the axle to overcome
the unevenness of the ground. LIM--SLIP self--locking differential lock
OP. 25 102 27
FRONT AXLE DIFFERENTIAL
WITH LIM--SLIP UNIT
Overhaul
WARNING
1. Remove the bevel drive--differential casing as-

sembly from the front axle, attach to support
293743 (4), lock in a vice and proceed with disas-
sembly operations as follows.
2. Remove the bolts (2) and the right--hand (Gd) and
left--hand ring nut lock plates (3).
3. Check that the right and left--hand caps (1) are
clearly marked, so as not to interchange the parts
during assembly operations.
4. Remove the right and left--hand bearing adjust-
ment ring nuts (Gd) from the ring gear.
5. Remove the bolts (C9) caps (1) and separate the
ring gear from the bevel pinion support.
6. If necessary, unscrew the retaining bolts (C1, 110
page 4) and remove the ring gear.
Disassemble the LIM--SLIP self--locking differential

lock as follows.
7. Remove the retaining bolts (1) from the differen-

tial half--casing.
8. Open the differential casing (6).
9. Remove the half--casing (7) the differential pin
(4), complete with the planet gears (3), the thrust
washers (2) and the pins (9).
10. Remove the side gear (5), the friction disk (11),
the metal disks (10) and the friction disks (12).
11. Remove the side gear (5), the friction disk (11),
the metal disks (10) and the friction disks (12)
from the half--casing (8).
12. Check the wear on the metal disks (10) and the
friction disks (11 and 12, see table below), replac-
27966
ing parts that show signs of wear.
13. Proceed with self--locking differential assembly
operations, carrying out the previously described
operations in reverse order, apply LOCTITE 270
to the threads on the screws (1) and tighten to a 111
torque value of 50 Nm (37 ft-lbs). LIM--SLIP self--locking differential lock
14. Refit the crown wheel (if previously disas-

sembled) on the half--casing (8), tightening the
bolts to a torque value of 113 Nm (83 ft-lbs).
15. Check the rolling torque of the bevel pinion, as in-
dicated earlier in this section.
16. Assemble the crown wheel, complete with LIM--
SLIP self--locking differential lock, on the bevel
drive support, remembering to fit the previously z
marked crown wheel bearing support caps in the
correct order and assemble and adjust the crown 27967
wheel bearings as indicated earlier in this section.
112
Friction parts detail
LIM--SLIP self--locking differential lock friction disks
Thickness Maximum wear per disk

Part no. Description Quantity
mm (in.) mm (in.)
10 Metal disk 10 1.5 (0.0591) --
11 Friction disk 2 2.8 (0.1102) 0.10 (0.0039)
12 Friction disk 8 1.6 (0.0630) 0.15 (0.0059)

OP. 44 511 80
LEADING DRIVE WHEELS TOE--IN CHECK
When travelling in a straight line, the wheels on four--

wheel drive models must be parallel to the longitudi-
nal axis of the tractor. A slight toe--in of the front
wheels is permissible -- up to a maximum of 6 mm
(0.2362 in.), as measured at the edges of the wheel
rims.
To check the exact value of the toe--in setting of four--

wheel drive tractors, proceed as follows.
1. Inflate the front tyres to the prescribed pressure.
2. Position the steering wheel at the middle of its

travel, with one spoke along the longitudinal axis
of the tractor.
3. Check that the wheels are parallel with the longi-

tudinal axis of the tractor.
1
4. Measure the distance (1) between the front in-
side edges of the rims.
5. Turn both front wheels through 180o then, at the 2
height of the wheel hub centres, measure the dis-
tance (2) between the rear inside edges of the
wheel rims, checking that the new measurement
is equal to or greater than distance (1) by a maxi-
mum of 6 mm (0.2362 in.). The rotation of the
wheels through 180o is required in order to elimi-
24666
nate the effect on the measurement of any even-
tual wear on the rims. 113
6. If wheel toe--in needs to be adjusted, remove nut

(2) and extract the track rod end (1) from the 1
housing.
Loosen lock nut (3) and screw the track rod end
(1) in or out to decrease or increase the distance
(2, fig. 113).
Reposition the track rod end (1) in the housing and
check the toe-in as described in steps 4 and 5.
After having adjusted the toe--in to within the pre-
scribed limits, tighten lock nut (3) to a torque val-
ue of 180 Nm (132 lfb.lb) and nut (2) to100 Nm (74
lfb.lb). 3 2
24667
114
NOTE: Self--locking nut (2) must be replaced each

time it is removed or unscrewed.
SECTION 27 -- REAR MECHANICAL TRANSMISSION -- CHAPTER 1 1
SECTION 27 -- REAR MECHANICAL TRANSMISSION
Chapter 1 -- Rear Mechanical Wheel Drive
CONTENTS

27 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
27 106 16 Rear Transmission/Gearbox, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
27 110 10 Differential Lock Engagement Sleeve, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
27 120 10 Final Drive Housing Assembly, Removal--Installation
27 120 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
27 120 34 Drive Wheel Shaft, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
27 120 32 Epicyclic Final Drive, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MAIN SPECIFICATIONS -- BEVEL GEAR PAIR AND DIFFERENTIAL

Bevel gear pair ratio:
-- model TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/38 = 1:4.2
-- models TN 65, TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . 9/40 = 1:4.4
Clearance between sides of bevel gear pair teeth . . . . . . . . . . mm 0.18 to 0.23
(in.) (0.0071 to 0.0091)
Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with two crown wheel gears
Mechanically controlled differential lock . . . . . . . . . . . . . . . . . . . pedal operated
Side pinion internal seat diameter (5, fig. 8) . . . . . . . . . . . . . . . mm 24.040 to 24.061
(in.) (0.9465 to 0.9473)
Side pinion pin diameter (19, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . mm 23.939 to 23.960
(in.) (0.9425 to 0.9433)
Clearance between side pinions and pins . . . . . . . . . . . . . . . . . mm 0.080 to 0.122
(in.) (0.0031 to 0.0048)
Diameter of crown wheel pinion hub seats on differential
housing (3, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44.080 to 44.119
(in.) (1.7354 to 1.7370)
Diameter of crown wheel pinion hubs (17, fig. 8) . . . . . . . . . . . mm 43.961 to 44.000
(in.) (1.7307 to 1.7323)
Clearance between crown wheel pinion hubs and seats . . . . . mm 0.080 to 0.158
(in.) (0.0031 to 0.0062)
Bevel gear bearing adjustment and bevel pinion clearance . . see pages 21 to 24
Thickness of bearing adjuster rings and bevel gear clearance
(21, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.15 -- 0.20 -- 0.50
(in.) (0.0059 -- 0.0079 -- 0.0197)
2 SECTION 27 -- REAR MECHANICAL TRANSMISSION -- CHAPTER 1
MAIN SPECIFICATIONS -- BEVEL GEAR PAIR AND DIFFERENTIAL

(continued)
Clearance between sides of planet and side pinion teeth . . . . mm 0.15

(in.) (0.0059)
Thickness of differential crown wheel shim adjustment rings
(16, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.4 -- 1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2.0
(in.) (0.0551 -- 0.0591 -- 0.0620 -- 0.0670
-- 0.0701 -- 0.0748 -- 0.0787)
Thickness of differential side pinion shim adjustment rings

(4, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.470 to 1.530
(in.) (0.0579 -- 0.0602)
Adjustment of clearance between the side pinion and crown
wheel teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see pages 24 and 25
Adjustment of differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 20

Thickness of differential lock control fork adjuster . . . . . . . . . . mm 0.5
(in.) (0.0197)
Differential lock control fork spring (Mechanical control):

-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 220
(in.) (8.6615)
-- length of spring under load of 177 to 195 N
(18.1 to 19.9 kg; 39.9 to 43.9 lb.) . . . . . . . . . . . . . . . . . . . . . mm 157.5
(in.) (6.2008)
MAIN SPECIFICATIONS -- LATERAL FINAL DRIVES
TN 55 TN 65 -- TN 70
TN 75
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . epicyclic with three side pinions and

spur gear
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13:(13+65)=
1:6
Thickness of side pinion shim rings (8, fig. 8) . . . . . . . . . . . . . mm 1

(in.) (0.0394)
Adjusting axial clearance of side pinion casing . . . . . . . . . . . . . see page 31
Thickness of axial clearance adjuster rings for side pinion

casing (10, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.5 -- 4.6 -- 4.7 -- 4.8 -- 4.9 -- 5.0 -- 5.1
(in.) -- 5.2 -- 5.3 -- 5.4 -- 5.5 -- 5.6 -- 5.7 --
5.8
(0.1772 -- 0.1811 -- 0.1850 -- 0.1890
-- 0.1929 -- 0.1968 -- 0.2008 -- 0.2047
-- 0.2087 -- 0.2126 -- 0.2165 -- 0.2205
-- 0.2244 -- 0.2283)
TORQUE SETTINGS
Tightening torque
PART Thread
Nm lfb.lb
Transmission gearbox -- clutch retaining bolts (C1, fig. 1) . . . . . . -- 117 to 129 86 to 94
Transmission gearbox cover -- PTO retaining bolts (C2) . . . . . . . . -- 20 to 25 14 to 18
PTO driven shaft ring nut (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 256 to 309 188 to 228
Transmission gearbox lower cover retaining bolts (C4) . . . . . . . . . -- 43 to 51 32 to 38
Bevel pinion shaft ring nut (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 280 to 309 206 to 228
Gear driven shaft bearings retaining bolts (C6) . . . . . . . . . . . . . . . -- 84 to 93 62 to 69
Crown gear wheel retaining bolts (C7) . . . . . . . . . . . . . . . . . . . . . . . -- 131 to 144 96 to 106
Reduction shaft bearings support retaining bolts (C8) . . . . . . . . . . -- 47 to 51 35 to 38
Reduction gearbox -- transmission gearbox retaining bolts (C9) . -- 135 to 149 100 to 110
Drive wheel axle retaining bolts (C10) . . . . . . . . . . . . . . . . . . . . . . . . -- 285 to 345 210 to 255
Plate disk -- drive wheel hub retaining bolts (C11) . . . . . . . . . . . . . -- 264 to 319 195 to 235
Plate disk -- drive wheel rim ring nut (C12) . . . . . . . . . . . . . . . . . . . . -- 217 to 262 159 to 193
TORQUE SETTINGS
C2 -- 20 to 25 Nm
C1 -- 117 to 129 Nm
Z=43
C6 -- 84 to 93 Nm C5 -- 280 to 309 Nm C4 -- 43 to 51 Nm C3 -- 256 to 309 Nm
C9 -- 135 to 149 Nm
C7 -- 131 to 144 Nm C8 -- 47 to 51 Nm
C10 -- 285 to 345 Nm
C11 -- 264 to 319 Nm
C12 -- 217 to 262 Nm
25999
1
TOOLS List of specific tools required for the various opera-

tions described in this section.

cannot be carried out without the ESSENTIAL tools
291517 Clutch casing lift hook.
marked with an (X).
sults, it is also necessary to use the recommended 290090 Rotating stand for overhaul opera-
specific tools listed below and certain other tools tions.
which are to be made according to the drawings inclu-
ded in this manual.
294088 Grooved wrench for bevel gear.
24663
2
(Stamp No. 50091 on the tool -- Measurement in mm)
Construct in Aq 42 D material.
1. Make 2 tie--rods in C 40 bon material.
26258
3
(Mark tool No. 50114 -- Measurement in mm)
26260
4
Tool to be constructed for adjusting differential lock sleeve travel.
(Stamp number 50041 on the tool -- Measurement in mm)
Construct in C40 material.
26000
5
Tool to be constructed for securing the transmission gearbox to the rotating stand.
(Stamp number 50156 on the tool -- Measurement in mm)
Construct in Aq 42 material -- (1) Rotating stand axle
6
Series of guide pins (no. 2) to be constructed for differential support removing--refitting.
(Stamp number 50164 on the pins -- Measurement in mm)
Construct in C40 material
1 2 3 4
11 10 9 8 7 6 5
26001
7
Longitudinal section of gearbox--transmission gearbox
1. Gearbox driving shaft. sleeve.

2. PTO control shaft. 7. Low -- mid driven gear shaft.
3. Gearbox driving gear. 8. Low -- mid -- upper range gear engagement.
4. Bevel gear. 9. Gearbox driven shaft.
5. Bevel pinion shaft. 10. 1st and 2nd gear engagement synchroniser.
6. Gearbox low -- mid -- upper range gear engagement 11. 3rd and 4th gear engagement synchroniser.
1 2 3 4 5 6 7 8 9 10 11 12
16 15 14 13
21 20 19 18 17
26002
Sectional view of transmission
A. 8.1 to 8.2 mm (0.3189 to 0.3228 in.). Differential lock 10. Side pinion casing support (13) axial clearance adju-
engage sleeve travel. ster shim.
B. 0.2 to 0.4 mm (0.0079 to 0.0157 in.). Lateral final 11. Wheel half--axle.
drive side pinion casing clearance. 12. Seal.
1. Ring bevel gear bearing support. 13. Lateral final drive side pinion casing support.
2. Differential lock control fork. 14. Lateral final drive side pinion.
3. Differential casing. 15. Bearing.
16. Crown wheel clearance adjuster ring.
4. Shim ring.
17. Crown wheel.
5. Side pinion.
18. Bevel gear.
6. Differential lock spring.
19. Side pinion pin (5).
7. Ring bevel gear bearing support. 20. Differential lock engagement sleeve.
8. Shim ring. 21. Adjuster rings for bearings and coupling clearance
9. Differential output half--shaft. between ring bevel gear and pinion.
The rear transmission transmits drive from the gear- a mechanically or hydraulically operated differential
box to the lateral final drives by means of the bevel lock.
gear pair. The bevel gear pair is of the helical tooth The lateral final drives are of the epicyclical type and
type and is supported by taper--roller bearings. are operated by the bevel gear pair output half shafts,
The differential has two side pinions and is fitted with the same shafts that control the service brakes.
BEVEL GEAR PAIR AND DIFFERENTIAL TROUBLESHOOTING
Transmission is noisy while the 1. Incorrect adjustment or wear Remove the rear transmission gear-
tractor is moving, even when the of crown wheel or side pinion box and replace the worn parts, then
gears are in neutral (not due to lat- gears. correctly adjust the differential gears
eral final drives). (page 24).
2. Excessive clearance between Remove the rear transmission gear-

half--shaft keyed groove and box and replace the damaged parts.
side pinion gears.
Transmission is noisy when trac- 1. Internal part faulty. Remove the rear transmission gear-
tor is under or released from load. box and replace the worn parts, then
correctly adjust the differential gear
clearance (page 24).
Transmission is noisy and assem- 1. Insufficient coupling clearan- Remove the rear transmission gear-
bly overheats. ce between the teeth of the pi- box and correctly adjust the ring bevel
nion and the ring bevel gear. gear bearings (page 21).
LATERAL FINAL DRIVES TROUBLESHOOTING
Lateral final drives are noisy while 1. Internal part faulty. Remove the lateral final drive housing
the tractor is moving, even when and replace the damaged parts.
the gears are in neutral.
neutral
2. Excessive clearance between Remove the lateral final drive housing
wheel axle shaft spline and and replace the damaged parts.
epicyclic final drives.
Op. 27 106 16
REAR TRANSMISSION GEARBOX
WARNING
To remove the gearbox, proceed as follows:
1. Carry out operation 21 118 10 or 21 118 12: Rear

transmission--gearbox, only removal (see Sec-
tion 21, Chapter 1).

gearbox, only gearbox removal (see Section 21,
Chapter 1).
3. Carry out operation 31 112 20 Mechanically en-

gaged PTO, only removal (see Section 31, Chap-
ter 1).
26003
4. Remove the pin (1) from the differential lock fork
(2). 9
5. Unscrew the retaining bolts (1) differential lock

rod (2) sto plate.
26004
10
6. Extract the differential lock rod (1) removing the
fork (2) and the return spring (3) from inside the
26005
11
7. Unscrew the retaining bolts (1) that support the

ring bevel gear (2), removing the supports and
adjuster shims.
26007
12
8. Remove the ring bevel gear (1) from inside the
26008
13
9. Extract the two sto pins (1) of the final drive con-
trol.
26009
14
10. Unscrew the rod support retaining bolts (1).
26010
15
11. Extract the retaining pins (1) of the fork and final
drive control nib.
26011
16
12. Remove the two rods (1), the forks and the final
drive control nib (2) with the relative poppet balls
and return spring from the front section of the
26012
17
13. Remove the retaining circlip (1) from the pinion
shaft rear gear (2).
26013
18
14. Remove the pinion shaft rear gear (1).
26014
19
15. Remove the pinion ring nut safety tab pressure

washer (1).
26015
20
16. Rotate the transmission gearbox (3) through
180°.
Fit tool 294088 (1) on the rear of the pinion shaft,
position the 55 mm wrench (2) on the internal ring
nut; using tool 294088 unscrew the ring nut and
take out the pinion shaft from the rear of the trans-
mission gearbox.
26016
21
17. Remove the gears (1) from inside the transmis-
sion gearbox (1).
18. To refit the various parts in the rear transmission
gearbox, proceed as follows.
WARNING
-- With the transmission gearbox facing upwards,

place the gears and the pinion shaft in the hous-
ing, via the opening on the PTO housing. 26017
-- Insert the 55 mm wrench on the internal ring nut

22
and, using a dynamometric wrench and tool
294088, move the end of the pinion so as to tight-
en the ring nut to a torque of 280 to 309 Nm (206
to 228 lfb.lb) and squeeze the safety washer.
-- Insert the remaining gears on the pinion shaft.
-- Fit the two rods, forks and final drive nib.
-- Check the rolling torque of the pinion, as de- -- Fit the differential lock rod with the fork control
scribed on page 21. piston and return spring.
-- Fit the rods, the pinion shaft sleeve forks and the
-- Adjust the position of the differential lock engage-
drive shaft sleeve with relative poppet balls and
ment sleeve as described on page 20.
return spring and the rod limit switch pins.
-- Before fitting the ring bevel gear, check and (if -- Carry out operation 31 112 20 Mechanically en-
necessary) adjust the clearance between the gaged PTO, only installation (see Section 31,
side pinion teeth and the crown wheels, as de- Chapter 1).
scribed on page 24.
-- Position the ring bevel gear inside the transmis- -- Carry out operation 21 118 85 Transmission gear-
sion gearbox, fit the LH ring bevel gear support box, only installation of gearbox in housing (see
with the 0.5 mm (0.0197 in.) test shim. Section 21, Chapter 1).
-- Adjust the ring bevel gear bearings and the clear- -- Carry out operation 21 118 10 or 21 118 12: Rear
ance between the sides of the ring bevel gear transmission--gearbox, only installation (see
teeth, as described on pages 21 to 24. Section 21, Chapter 1).
27153
27153
SECTION 27 -- REAR MECHANICAL TRANSMISSION -- CHAPTER 1
Diagram for application of sealing compound for rear transmission--gearbox

The types of sealing compound are indicated on page 1, Section 00
17
Op. 27 110 10
Adjusting the position of differential lock
engagement sleeve
WARNING
Proceed as follows.
1. Fit the differential lock control device or the plate

without the adjuster shim.
2. Insert gauge 50041 (2, fig. 4) with the 8.1 to 8.2

mm (0.3189 to 0.3228 in.), shim between the
sleeve and the differential housing, so that it
makes contact with the sliding surfaces of the
sleeve on the housing.
3. Using a crowbar, bring the sleeve into contact

with the gauge 50041 and the differential hous-
26018
ing, adjusting the fork (1) to the position of the
gauge. 23
4. Using a feeler gauge (1), measure the clearance

between the control pin (2) and the seat on the
rod (3).
26019
24
5. Position the required shim under the differential
lock control device (mechanically operated mod-
el) or under the plate (2) (hydraulically operated
model) and secure in position using the bolts.
26020
25
Adjusting the ring bevel gear bearings and

checking the clearance between the sides of
the bevel gear pair teeth
ATTENTION
Proceed as follows.
1. Fit the bevel pinion, together with the relevant

parts, and tighten the ring nut to a torque of 280
to 309 Nm (28.5 to 31.5 kgm).
2. Check that the pinion rolling drag torque is 0.040

to 0.450 kgm, corresponding to a dynamometric
force on the mid--upper driven gear range of 5.9
to 62.8 N (0.6 to 6.4 kg).
3. With the bevel pinion fitted, insert the differential

assembly complete with the ring bevel gear. Fit
the LH support (1) on the transmission--gearbox,
with a test shim of 0.5 mm (0.0196 in.), tightening 26021
the three bolts at 1205, to a torque value of 59 Nm
(6 kgm 120). 26
4. Using a micrometer gauge (1), measure the thick-

ness of the RH support (D1). Fit the support (2),
without adjuster rings, on the transmission--
gearbox, using the three lubricated bolts set at
120°.
26022
27
5. Tighten the bolts gradually and alternately and, at
the same time, turn the crown wheel to allow the
bearings to settle, until the pinion crown reaches
a rolling torque which is the same as that
measured for the single pinion plus the values
shown in the table:
ROLLING CROWN
9/40 9/38
0.88 to 1.32 Nm
7.7 to 11.6 ins.-lbs.
This torque can be measured with a spring scale

(1) and cord wrapped around the mid--upper gear
drive and corresponds to a force on the dy-
namometer for the single pinion, added to the val-
ues shown on the table:
ROLLING CROWN
9/40 9/38
12.7 to 19.6 Nm
9.4 to 14.4 ft.-lbs.
26023
28
6. Use a depth gauge to measure the distance (D2)
between the transmission--gearbox and the outer
face of the RH support, near the two notches, and
calculate the arithmetic mean of the two
measured values.
26024
29
7. Use a depth gauge to measure the distance (D3)
between the transmission--gearbox and the RH
support seat, near the two notches, and calculate
the arithmetic mean of the two measured values.
8. The total thickness of the shims to be inserted
under the RH and LH supports is given by:
S = D3 -- D1 -- D2 + 0.05 mm
(S = B3 -- D1 -- D2 + .002 ins.)
where:
S = total thickness to be insert (excluding the test
shim). 26025
D3, D2 and D1 = distances measured. 30
0.05 mm (0.0019 in.) = oversizing required to re-

duce the preload on the bearings generated by
the support retaining bolts. If necessary, round up
the value (S) to the nearest 0.05 mm (0.0019 in.).
9. Using a dial gauge (1), check the clearance (G)

between the sides of the teeth of the bevel gear
pair (three measurements at 120° and the arith- 1
metic mean of the three readings) and compare
the mean of the three values with the normal pre-
scribed clearance: 0.18 to 0.23 mm (0.0071 to
0.0091 in.), average value 0.21 mm (0.0083 in.).
To compensate for greater measured clearance,
consider that the ratio between the normal clear-
ance of the teeth and the equivalent axial move-
ment of the crown wheel has an average value of
1 : 1.4.
The axial movement of the crown (Z) will there- 26026
fore be: 31
Z = (G -- 0.21 mm) x 1.4
(Z = [G -- .008 ins.] x 1.4)
where:
G = previously measured clearance between the
sides of the teeth of the bevel gear pair.
10. The sets of adjuster rings (Sd and Ss) to be in-

serted on the RH (2) and LH (1) supports are giv- Ss Sd
en by:
Sd = S -- Z 1 2
Ss = Z + 0.5 mm (Ss = Z + .019 ins.)
where:
S = Overall value of adjuster rings (excluding the

test shim).
Z = Axial movement of the crown wheel previous-

ly calculated. 25930
0.5 mm (.019 ins.) = Test shim. 32
11. Fit the calculated shims on the supports and

check the rolling torque of the pinion--crown
wheel assembly and the clearance between the
sides of the teeth of the bevel gear pair as de-
scribed above.
Example
-- Measurement of rolling torque of the bevel pinion
shaft = 0.39 to 4.4 Nm (0.3 to 3.2 lfb.lb) (on the
spring scale 5.9 to 62.8 Nm -- 4 to 46 lfb.lb).
-- Measurement of thickness (D1) of the RH support
= 12.05 mm (0.4744 in.).
-- Measurement of rolling torque of the pinion-- 26027
crown wheel assembly = 3.14 Nm (2,3 lfb.lb), cor-
responding to the force on the spring scale with 33
a cord wrapped around the mid--upper range
gears of 45.1 N (4.6 kg -- 10.1 lb.).
-- Measurement of distance (D2) between the
transmission--gearbox and the RH support: 30.05
mm (1.1831 in.); 30.15 mm (1.1870 in.).
30.05 + 30.15
D2 = mean = = 30.10 mm
2
[1.183 + 1.187 = 1.1850 in.]
2
-- Measurement of distance (D3) between the
transmission--gearbox and the RH support seat:
42.80 mm (1.6850 in.); 43.00 mm (1.6929 in.).
42.80 + 43.00
D3 = mean = = 42.90 mm
2
[1.6850 + 1.6929 = 1.6890 in.]
2
-- Total thickness of the adjustment rings:
S = 42.90 -- 12.05 -- 30.10 + 0.05 = 0.80 mm
(1.6890 -- 0.4744 -- 1.1850 + 0.0020 = 0.3150 in.).
-- Clearance measured between sides: 0.43 mm
(0.0169 in.); 0.45 mm (0.0177 in.); 0.41 mm
(0.0161 in.).
0.43 + 0.45 + 0.41
G = mean = = 0.43 mm
3
[.0169 + .0177 + .0161 = 0.0169 in
3
-- Axial movement (Z), corresponding to the set of
shims to be inserted on the LH support:
Z = (0.43 -- 0.21) x 1,4 ≅ 0.30 mm [(0.0169 --
0.0083) x 1.4 ≅ 0.0118 in.].
-- Thickness of adjuster rings to be inserted on the
RH support Sd = 0.80 -- 0.30 = 0.50 mm (0.3150--
0.0118 = 0.0197 in.). Thickness of adjuster rings
to be inserted on the LH support Ss = 0.30 + 0.50
= 0.80 mm (0.0118 + 0.0197 = 0.3150 in.).
where:
0.50 mm (.020 ins.) = test shim.
Adjustment of the clearance between the side

pinion and crown wheel teeth 1 2 3 4 5
With the differential disassembled on the bench, pro-
ceed as follows. 6
12. Fit the two crown wheels (2 and 5) without rings
(1 and 6) on the differential housing. Insert the
side pinions (3 and 8) complete with fifth wheel 7
ring adjustment and pin (7); turn the retaining
bolt(4) a few times to prevent the pin from sliding
out. 8
25920
34
13. Manipulate the LH crown wheel, so that it comes
into contact with the side pinion and, using a
depth micrometer, measure the distance (H1),
taking two diametrically opposed measurements,
taking the arithmetic means of the two values
measured.
H1
25921
35
14. Push the crown wheel so that it touches the dif-
ferential and measure the distance (H2).
15. Repeat the same operations for the RH crown
wheel.
25922
H2
36
16. The axial movement of the crown wheels (2 and

5) without adjustment rings is given by: 1 2 3 4 5
Gs or Gd = H1 -- H2
where: 6
Gs = axial movement of LH crown wheel;
Gd = axial movement of RH crown wheel;
H1 and H2 = the LH or RH crown wheel measure- 7
ments.
The normal clearance envisaged between the 8
sides of the side pinion teeth is 0.15 mm (.006 ins.).
Therefore, the normal clearance and the equiva- 25920
lent axial movement of the crown wheels has an

average ratio of 1:1.7. 37
The axial movement of the crown wheels corre-
sponding to the normal clearance is:
0.15 x 1.7 = 0.25 mm (0.0059 x 0.0669 = 0.0098
in.).
Therefore the adjustment rings (1 and 6) to insert
on the differential housing will be given by:
Ss = Gs -- 0.25 mm (.001 in.) (for LH crown
wheel).
Sd = Gd -- 0.25 mm (.001 in.) (for RH crown
wheel).
Insert the adjustment rings obtaining a distance
which is as close as the value thus obtained (the
available values are listed on page 2).
Adjustment of the differential lock control pedal

stroke
The distance (H) between the pedal base and the end
of the lining should be 58 to 62 mm (2.2835 to 2.4409
in.).
38
If not, proceed as follows.
1. Loosen the locknut (1), unhook and extract the

sto spring (2).
2. Screw or unscrew the fork (3) until the required

height for the differential lock pedal from the base
is obtained.
3. Insert and hook--up the sto spring and tighten the

locknut. 39
Op. 27 120 10 -- 27 120 20

RH OR LH LATERAL FINAL DRIVE
HOUSING ASSEMBLY
DANGER
equipment.
lifted.
Proceed as follows:
2. Carry out operation 90 114 26: Rear roll bar, only

3. To remove the LH final drive housing, carry out

operation 10 216 10: Fuel tank, only removal (see
Section 10, Chapter 1).
4. Unscrew the retaining bolts holding the lateral

stabiliser strut. 40
5. Fit tool 50091 (1) and adapter 50114 (2) to the fi-
nal drive housing (3), then position a hydraulic
jack (4) under the tool.
41
6. Unscrew the retaining bolts and, using the hy-
draulic jack, remove the final drive housing (1)
and the axle shafts.
7. To refit the lateral final drive housing, proceed as

follows.
WARNING
42
-- Before refitting the housings, supports and cov- -- Fit the lateral stabiliser strut bracket.
ers clean and de--grease the mating surfaces and
apply sealing compound (approx. 2 mm -- 0.0787
in. -- in diameter) as shown in figure 43. -- If the LH final drive is removed, carry out opera-
tion 10 216 10 : Fuel tank, only installation (see
-- Insert the axle shaft in the brake disk and differen-
tial.
-- Using tools 50091, 50114 and a hydraulic jack, re-
fit the lateral final drive unit to the rear transmis- -- Carry out operation 90 114 26: Rear roll bar, only
sion gearbox. installation (see Section 90, Chapter 1).
27154
43
Diagram of seal compound application for brake assembly and lateral final drives on the transmission gearbox.
The types of sealing compound are indicated on page 1 section. 00.
Op. 27 120 34
DRIVE WHEEL SHAFT
WARNING
With the lateral final drive housing removed from the

rear transmission, proceed as follows.
26030
1. Remove the drive wheel shaft lock bolt safety
plate (1). 44
2. Unscrew the bolts securing the driven gear sup-

port (1) on the drive wheel shaft and remove the
safety plate.
26031
45
3. Extract the support (1) from the driven gears and
remove the axial clearance adjuster shim from
the support.
26032
46
4. Connect the lateral final drive (1) to a hoist (2) and

raise, checking that the wheel axle leaves the
housing (tap on the end of the driving gear axle
with a rubber mallet to ease it out).
26033
47
5. Remove the seal (1).
6. To refit the lateral final drive housing, proceed as

follows.
WARNING 1
-- For the positioning of the various parts refer to fig-

ures 7 and 8. 24614
-- Respect the tightening torques prescribed on 48

page 3.
-- Fit the seal using a suitable striker.
-- Assemble the drive wheel shaft.
-- Fit the driven gear support and the relative adjust-

er shim.
-- Insert the safety plate and tighten the bolt to the

prescribed torque.
-- Adjust the axial clearance of the gear support as

follows.
7. Using a dial gauge (1), check that the axial clear-

ance of the support (2) is 0.2 to 0.4 mm (0.0079
to 0.0157 in.); if not, change the adjuster shim
(10, fig. 8).
26034
NOTE: The adjustment shims are listed on page 2.
49
Op. 27 120 32
EPICYCLIC FINAL DRIVE
WARNING
With the assembly detached from the housing, pro-

ceed as follows.
1. Remove the retaining ring (1).
2. Extract the pins and remove the gears, complete

with the roller bearings.
24620
3. Fit all the parts of the epicyclic final drive, revers-
ing operations 1 and 2. 50
SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1 1
SECTION 31 -- MECHANICAL POWER TAKE--OFF
Chapter 1 -- Mechanical Power Take--Off
CONTENTS
31 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
31 112 20 Mechanical power take-off, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAIN DATA
PTO 540 rpm TN 55 TN 65 -- TN 70

TN 75
Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1) independent with respect to

tractor speed
or:
2) synchronized to gearbox
Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, by means of hand

lever located under the steering
wheel, on RH side
(see page 9 and 10)
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . . clockwise

Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . . rpm 2196
PTO revolution speed with engine at max. power of
2300 rpm: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- PTO 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 565
540 rpm, gearbox synchronized, PTO revolution speed rev/
(30 km/h -- 18.6 mph -- model) . . . . . . . . . . . . . . . . . . . . . . . . wheel 15.23 16.69
rev
Diameter of driven shaft at bearings . . . . . . . . . . . . . . . . . . . mm 49.938 to 50.000
(ins) (1.9661 to 1.9685)
Diameter of driven shaft at grooved terminal . . . . . . . . . 13/8” (6 grooves)
2 SECTION 31 -- MECHANICAL POWER TAKE--OFF -- CHAPTER 1
MAIN DATA
(continued)
PTO 540 TN65 -- TN 70
TN55
TN75
External diameter of driven gears support bushings . . . . . . mm 45.925 to 45.950
Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . . mm 46.050 to 46.075

(in.) (1.8130 to 1.8140)
Clearance between driven gears . . . . . . . . . . . . . . . . . . . . . . mm 0.100 to 0.150
(in.) (0.0039 to 0.0059)
Diameter of driven shaft at front and central bushings . . . . mm 37.966 to 37.991
(in.) (1.4947 to 1.4957)
Diameter of driven shaft at rear bushing ............... mm 34.966 to 34.991
(in.) (1.3766 to 1.3776)
Internal diameter of front and central bushings . . . . . . . . . . mm 38.000 to 38.039
(in.) (1.4961 to 1.4976)
Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . . mm 34.000 to 34.039
(in.) (1.3386 to 1.3401)
Clearance between shaft and front and central bushings . . mm 0.009 to 0.073
(in.) (0.0004 to 0.0029)
Clearance between shaft and rear bushing . . . . . . . . . . . . . . mm 0.009 to 0.073
(in.) (0.0004 to 0.0029)
TOOLS

must only be performed with the ESSENTIAL tools
marked with an (X).
X 294145 Striker for PTO driving shaft bearing

(with 294099).
X 294099 Hand grip (with 294145 or 294100).
X 294100 PTO driving shaft seal splining tool 1

(with 294099).
X 294092 Grooved guide for synchronized PTO

shaft hub installation.
Tool to be made to remove--install the PTO shaft (stamp 26636

number 50159 on the tool-- Measurement in mm)
Construct in C40--(1) CH 36 hexagonal. 1
TORQUE SETTINGS
C1 --21Nm (14 ft-lbs)
C4 --294Nm (217 ft-lbs)

27853
2
PTO 540 rpm
TORQUE SETTINGS
Tightening torque
PART Thread
Nm lfb.lb
Bearing support retaining bolts . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 72
PTO cover retaining bolts (C1) . . . . . . . . . . . . . . . . . . . . . -- 21 14
Self locking nut for driven gears shaft: (C4) . . . . . . . . . . M 32 x1.5 294 217
2 1
12
3 4
6
7
11
27854
9
8
10
3
Longitudinal sectional diagram of 540 rpm PTO
1. 540 rpm PTO cover. 7. Rear transmission housing.

2. Drive shaft bearings. 8. Driven gear support bushing.
3. PTO shaft bearings. 9. Rear bearings support.
4. Seal ring. 10. 540 rpm driven gear.
5. Grooved terminal. 11. Driven gears shaft lock nut.
6. PTO cover retaining bolt. 12. Drive shaft.
DESCRIPTION AND OPERATION OF

MECHANICAL PTO
The PTO (1) installed on the tractor transfers motion

to the transported or towed implements. Control is ei-
ther directly from the engine clutch or from the gear-
box clutch.
Mechanically engaged/disengaged PTO devices are

available in one speed, 540 rpm.
PTO controlled directly from the engine clutch
Proceed as follows:
-- engage the clutch by moving the control lever (1)

to the horizontal position.
When engaged, the PTO grooved terminal rotates

and the relevant lamp on the dashboard illuminates. 5
In these conditions PTO operation is completely inde-
pendent from the tractor travel, therefore:
-- the tractor can be stopped without stopping the

PTO;
-- the PTO can be stopped without stopping the

tractor (by disengaging the PTO clutch);
-- disengage the PTO by moving the control lever

(1) to the vertical position. 6
PTO synchronized with gearbox (mechanically
controlled models).
Proceed as follows:
-- disengage the clutch control lever (1, fig. 6);
-- with the tractor stationary, fully press the engine
gear clutch pedal;
-- wait briefly, then move the lever (1) from position
D (PTO not synchronized) to position C (PTO
synchronized) and release the engine gear clutch
pedal.
PTO synchronized with gearbox (Power--Shuttle 7

models).
Proceed as follows:
-- disengage the clutch control lever (1, fig. 6);
-- with the tractor stationary, move the lever (1,
fig. 7) to position C.
In these conditions the PTO coupling sleeve (3) is di-

rectly driven by the toothed coupling of the gearbox
gear (1). 2 3
When the tractor is stationary, the synchronized PTO 1
does not rotate; when shifting from forward to re-
verse, the direction of terminal rotation is reversed.
WARNING
Do not engage the synchronized PTO when the trac-
tor is moving.
26044
NOTE: For models with mechanical gearboxes,
when the PTO is not in use, keep the clutch lever (1, 8
fig. 6) in the vertical position and the control lever (1,
fig. 7) in position B.
MECHANICAL PTO TROUBLESHOOTING
Faults Possible causes Remedies
Slipping with speed loss on PTO Wear of clutch disk or flywheel Check the data on the appropriate
grooved terminal. pressure plate. pages in Section 18, replace the worn
parts and adjust the clutch lever.
Incorrect adjustment of PTO
clutch lever.
Op. 31 112 20
MECHANICAL PTO
WARNING
Proceed as follows:
1. Carry out operation 21 118 10 or 21 118 12 Rear

transmission housing--gearbox, only removal
(see Section 21, Chapter 1).
26046
2. Remove the securing ring and extract the PTO
drive shaft rear cover (1). 9
3. Remove the front and rear rings (1) securing the

external PTO gearbox and remove the end of the
drive shaft.
26047
10
4. Remove the external PTO gear (1), through the
cover opening, together with the gear control rod
and final drive.
26048
11
5. From the same opening, also remove the syn-
chronized PTO gear (1).
26049
12
6. Remove the ring and extract the front PTO shaft
(1) recovering the synchronized PTO driven gear.
26050
13
7. Remove the retaining pins (1) securing the con-
trol lever (2).
26051
14
8. Remove the PTO driven shaft lock nut, using the
grooved wrench 50159 (1) and remove the driven
shaft.
26052
15
9. Unscrew the retaining bolts (1) from the PTO cov-

er (2) and remove the cover by means of the inter-
nal revs selection rod.
26053
16
10. Remove the external pin (2) and extract the PTO
revs selection rod (1).
26054
17
11. Remove the speed selection control cam , gears
and levers from the PTO housing.
12. To re--fit the PTO, proceed as follows.
WARNING
-- Fit the control levers and PTO gears in their seats.

-- Fit the PTO revs selection rod and insert the rod
securing pin.
26055
-- Fit the internal revs selection rod and the PTO cov-
er, securing in position with the bolts. 18
-- Fit the driven shaft in the PTO housing, tightening
the driven shaft lock nut with grooved wrench
50159.
-- Fit the control lever securing pin.
-- Insert the front PTO shaft, using the grooved
guide for fitting the synchronized PTO gear shaft
hub No. 294092 (1). When the gear is in its seat,
remove the grooved guide.
Fit the retaining ring on the shaft.
-- Insert the driven gear and the PTO external gear

from the cover hole, with gearbox command rods
and final drive.
-- Insert the terminal part of the drive shaft and install

the front and rear external PTO gear securing rings.
26056
-- Install the rear drive shaft cover and the respec-
tive fastening ring. 19
-- Carry out operation 21 118 10 or 21 118 12 Rear

transmission housing--gearbox, only installation
PTO CABLE
ADJUSTMENT/REPLACEMENT 2
3 1
ADJUSTMENT
1. From under the left side of the tractor between the
drive shaft and fuel tank, loosen jam nut (1).
2. Turn nut (2) clockwise or counter clockwise to
make the PTO cable (3) longer or shorter as
necessary.
3. Tighten jam nut (1).0475
50030475
20
REPLACEMENT
1. From under the left side of the tractor between the 2 4
drive shaft and fuel tank, loosen jam nut (1). 3 1
2. Turn nut (2) until the PTO cable (3) has no tension
on it.
3. Remove clip (4) and pin (5) from the PTO clutch
lever.
4. Slide the PTO cable (3) through slot (7).
7 5
50030475
21
5. From under the left rear corner of the platform,

remove clip (1) and pin (2) from the PTO control
lever. 2
6. Slide the PTO cable through slot (3). 1

7. Remove the PTO cable from the bottom of the
tractor. 3
8. Installation of the PTO cable follows the removal
procedures in reverse.
NOTE: Proper adjustment of the cable is required for 50030474

optimum PTO performance.
22
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 1
SECTION 33 -- BRAKING SYSTEM
Chapter 1 -- Braking System
CONTENTS
33 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
33 202 60 Right or left--hand brake, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
33 202 46 Braking system hydraulic pump, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
33 202 04 Brake hydraulic system -- Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
33 110 40 Parking brake, Brake disks Removal--Installation
33 110 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
33 110 08 Handbrake control, Travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MAIN DATA
Type:
-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with oil bath disk, acting on
differential drive shafts
-- parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with oil bath disks, engaging a
gear on the bevel pinion shaft
Control:
-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydrostatic, with independent
(connected by means of a pin)
-- parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, by means of a hand
lever
Service brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sintered
Parking brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel
Parking brake mobile sectors material . . . . . . . . . . . . . . . . . . . . . . . sintered
or
organic agglomerate
Disk thickness:
-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 10
(in.) (0.3937)
-- wear tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 8.6
(in.) (0.3386)
-- parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.95 to 4.05
(in.) (0.1555 to 0.1594)
2 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
MAIN DATA
(continued)
Parking brake friction disk thickness (mobile sectors):

-- side sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.1 to 3.4
(in.) (0.1220 to 0.1339)
-- intermediate sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.2 to 4.5

(in.) (0.1654 to 0.1772)
Hydrostatic control
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with 2 master cylinders

independently operated by brake
pedals
Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 17.6
(psi) (255.3)
Control pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . see page 14

Bleeding air from brake circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 15
TORQUE SETTINGS
Tightening torque
PART Thread
Nm lfb.lb
Nut securing final drive to transmission casing (C1) . . . -- 135 to 149 100 to 110
Guide bolts for parking brake mobile sector (C2) (:) . . -- 24 18

(:) Apply 2 drops of LOCTITE 243 thread lock.
C1 --135:149 Nm
C 2--24 Nm
26057 26058
1
8 9 1 2
60x95x23
26059
3 X
7
26060
5 4
2
Service brake and parking brake sectional drawings
1. Service brake disk. 6. Parking brake support.

2. Final drive casing spacer. 7. Seals.
3. Parking brake disks. 8. Brake control piston.
4. Braking sectors. 9. Guide grub screw.
5. Parking brake internal control lever.
NOTE: When fitting apply sealing compound to surfaces X as shown on page 10.
24664
3
Service brake sectional drawing
1. Spring. 4. Rear seals.

2. Pump body. 5. Central seals.
3. Control piston. 6. Front seals.
TOOLS specific tools listed below and certain other tools

Warning -- The operations described in this section cluded in this manual.
cated by an (X).
To work safely and efficiently and obtain the best re- List of specific tools required for the various opera-
sults, it is also necessary to use the recommended tions described in this section.
24663
4
(Stamp No. 50091 on the tool -- Measurement in mm)
Construct in Aq 42 D -- 1 material. Make 2 tie--rods in C 40 bon material.
26258
5
Tool to be made for removal--installation of the final drives, to be used with a part of 50091.
(Mark tool No. 50114 -- Measurement in mm)
Construct in Fe 42 C material -- (*) Define measurement according to the hydraulic jack seat.
SERVICE BRAKES The brake disks (one for each rear wheel) are located
between the rear transmission casing and the final
The service brakes are hydraulically operated with oil drive casing. The disks are splined on the differential
bath disks. drive shafts.
The two control pumps (one for each pedal) are lo-
cated in the front part of the cab and are connected
to their respective pedals by means of two tie--rods. PARKING BRAKE
These pumps can be operated individually or togeth- The parking brake is mechanically operated, by
er. If operated together, the pedals are connected by means of an intermediate gear on the rear bevel pin-
a pin. ion shaft, and is controlled by a lever located on the
left--hand side of the operator.
A connecting pipe between the two pumps ensures
balanced braking, even when the brake disks are not When the parking brake control lever is applied, the
equally worn. tie--rod acts on the external support lever and moves
the braking sectors up against the three brake disks
The two control pumps are fed from a single reservoir splined to the intermediate gear, thereby stopping the
positioned above the pumps. tractor.
BRAKE TROUBLESHOOTING
Brake pedals hard to operate. 1. Corresponding master cylin- Replace the brake control pump.
der seized.
2. Brake control pipes obstruc- Clean or replace the control pipes.

ted or pinched.
The brakes stick when the pedals 1. Brake control pump pistons Release the piston and, if necessary,
are released. locked. replace the brake control pumps.
2. Master cylinders seized. Replace the brake control pumps.
Noisy brakes. 1. Friction material on brake Replace the brake disks.

disks worn (1, fig. 2).
Pedal stroke too long. 1. Air in the brake circuit. Bleed air from the brake circuit.
2. Brake control pumps worn. Replace the brake control pumps.
3. Leakage from control pipes. Eliminate the cause of the leakage.
Unbalanced braking. 1. Incorrect tire pressure. Inflate the tires to the correct pres-
sure.
3. Pump connection pipes ob- Clean or replace the pipes.

structed or pinched.
4. Brake control pipes obstruc- Clean or replace the control pipes.

ted or pinched.
5. Pump control piston seals Replace the brake control pumps.

worn or damaged.
6. Friction material on brake Replace the disk.

BRAKE TROUBLESHOOTING
(continued)
Inefficient braking. 1. Friction material on brake Replace the brake disks.

3. Air in the brake circuit. Bleed air from the brake circuit.
4. Leakage from control pipes. Eliminate the cause of the leakage.
5. Pump control piston seals Replace the brake control pumps.

worn or damaged.
Parking brake does not lock. 1. Brake control incorrectly adju- Adjust correctly.
sted.
2. Braking sectors worn (4, fig. Replace the braking sectors.

2).
The tractor remains braked when 1. Control return stroke obstruc- Remove obstructions.
the parking brake is disengaged. ted.
2. Braking sectors (4, fig. 2) sei- Release and replace the damaged
zed on brake disks. parts.
p. 33 202 60
RIGHT OR LEFT HAND BRAKE
DANGER
equipment.
lifted.
26063
Proceed as follows:
1. Carry out operation 27 120 10 or 27 120 20: Right 6
or left--hand final drive casing, only removal (see
2. Remove the brake disk (1) from the seat in the
transmission casing (2) and recover the control
piston.
3. To refit the right or left--hand brake, proceed as

follows.
WARNING
-- Check the control piston seals and replace, if nec-

essary.
-- Fit the control piston (1) in the seat in the rear 26064
transmission casing (2), using a rubber mallet.
7
-- Fit the brake disk (1, fig. 6).
-- Carry out operation 27 120 10 or 27 120 20 : Right

or left--hand final drive casing, only installation
26254
8
Sealing compound application diagram for braking unit and final drives on transmission casing
The types of sealing compounds to be applied are specified on page 1 section. 00.
Op. 33 202 46
BRAKE HYDRAULIC PUMP
WARNING
To remove the hydraulic pump, proceed as follows.
1. Block the wheels using chocks.

only removal (see Section 90).

only removal (see Section 90).
4. Carry out operation 41 204 10: Hydrostatic steering

wheel, only removal (see Section 41, chapter (1).
5. Carry out operation 55 418 10: Multi--indicator

panel, only removal (see Section 55, chapter 7).
6. Remove the instrument panel upper guard retain- 9

ing bolts (1).
7. Remove the steering column dust guard (1).
10
8. Unscrew the retaining screw and remove the
handgrip (1) on the throttle lever.
11
9. Remove the fuse box cover (1), unscrew the re-

taining screws and remove the fuse box.
12
10. Unscrew the indicator lights switch ring nut.
13
11. Unscrew the retaining screw and remove the
lights switch knob (1).
14
12. Unscrew the lights switch retaining nut (1) and the
starter switch ring nut (2).
15
13. Remove all the electrical connections and re-

move the instrument panel upper guard (1).
16
14. Unscrew the retaining bolts and remove the lower
guard (1). (On both sides).
17
15. Remove the spring (1) and extract the pin (2) to
free the brake pedal. (On both brake pedals).
18
16. Disconnect the brake pump pressure switch con-
nection (1).
19
17. Disconnect the brake piping (2), remove the

pump connection pipe.
20
18. Disconnect the brake pump piping (1) and attach
to the reservoir, to avoid spilling the oil inside.
21
brake pump (1). Repeat operations for the other
brake pump.
20. To re--fit the brake pumps, proceed as follows:
WARNING
-- Position the brake pumps and secure.

-- Connect the pump infeed piping.
-- Attach the pump connection pipe.
-- Connect the brake control piping. 22
-- Connect the pressure switch.
-- Connect the brake pumps to the control pedals.
-- Fit the two lower guards.
-- Connect the electrical connections and position -- Fit the upper guards.
the upper guard.
-- Carry out operation 55 418 10: Multi--indicator
-- Tighten: the starter and lights switch ring nuts. panel ,only installation (see section 55, chapter
-- Assemble and secure the lights switch knob. 7).
-- Tighten the indicator lights switch ring nut. -- Carry out operation 41 204 10: Hydrostatic steer-
ing wheel, only installation (see section 41).
-- Position the fuse box, secure in position and fit
the cover. -- Carry out operation 90 100 84: Bonnet guard,
-- Assemble and secure the handgrip on the throttle only installation (see section 90).
lever.
-- Fit the hood on the steering column. only installation (see section 90).
Service brakes control pedals stroke adjustment.
WARNING
Proceed as follows.
21. With the brake pedals mounted and connected to

the relative pumps, and the spring connected,
check that the pin (1) enters the hole on the left--
hand pedal without obstructions. 23
22. If interference is detected, disconnect the spring
from the lower pedal, adjust the fork (1) in order
to eliminate the pin interference, then tighten the
locknut.
Connect the spring.
24
Op. 33 202 04
BRAKE HYDRAULIC SYSTEM
Air bleeding
Whenever service operations are carried out on the
brake hydraulic system, air bleeding must be per-
formed.
Proceed as follows:
1. Remove the cap and thoroughly clean the external
parts of the assemblies near the bleeding screws
and the hydraulic oil reservoir cover.
2. Check that the right--hand (2) and the left--hand
(1) brake reservoirs are full, both before and dur-
25
ing bleeding.
3. Push the left--hand brake pedal down, slowly
and fully, so that the oil is put in pressure.
4. Keep the pedal pressed down, unscrew the

bleeding screw (1) by half a turn, allowing the oil/
air bubble mixture to flow out.
5. Tighten the screw (1) and repeat the aforemen-
tioned operation until oil without air bubbles flows
out.
6. Push the brake pedal down again so that the oil
is put in pressure i.e.: when the brake pedal
stroke returns to normal.
7. Repeat the aforementioned operation on the
right--hand part of the brake circuit.
8. On completion of the operation, top up the oil lev- 26

el in the reservoir.
9. Thoroughly clean the external parts of the assem-
blies near the bleeding screws (1) and (2).
10. Push the left--hand brake pedal down, slowly
and fully, so that the oil is put in pressure.
11. Keep the pedal pressed down, unscrew the
bleeding screw (1) by half a turn, allowing the oil/
air bubble mixture to flow out.
12. Tighten the screw (1) and repeat the aforemen-
tioned operation until oil without air bubbles flows
out.
13. Push the brake pedal down again so that the oil
is put in pressure i.e.: when the brake pedal
stroke returns to normal. 27
14. Repeat the aforementioned operation on the
brake circuit screw (2).
15. On completion of the operation, to up the oil level
in the reservoir.
Op. 33 110 40 -- 33 110 44

PARKING BRAKE
Removal--Installation parking brake disks
WARNING
To remove the parking brake disks, proceed as fol-

lows:
1. Unscrew the cap and drain the oil from the rear
25628
litres; 11.1 gallons). 28
2. If fitted, Carry out operation 33 220 40: Trailer

brake valve, only removal (see Section 35, Chap-
ter 3).
3. Unscrew the four retaining bolts (1) and remove 1
the parking brake disks access guard (2).
26078
29
4. Remove the safety ring (1) from the parking brake
disks (2).
26080
30
5. Recover the safety ring (1), the brake disks (2)

and the friction disks (3).
6. To refit the parking brake disks, proceed as fol-
lows.
WARNING
-- Study the illustrations in fig. 2 for the positioning

of the various parts.
-- Insert the brake disks and friction disks in their re- 26081
spective seats.
31
-- Fit the safety ring.
-- Fit the access guard on the transmission casing
and secure with the four bolts.
-- If fitted, Carry out operation 33 220 40: Trailer
brake valve, only installation (see Section 35,
Chapter 3).
-- Tighten the cap on the rear transmission casing
and fill up with oil (for products and quantities see
Section 00, page 6).
Op. 33 110 08
HANDBRAKE CONTROL
Stroke adjustment
The parking brake lever must be adjusted whenever

service operations are carried out on the assembly,
and if the lever is not positioned in the third notch
when the brake is engaged.
Proceed as follows:
1. Turn the adjusting device (1) clockwise if the

parking brake lever has moved more than three
notches when the brake was engaged.
2. Check that the parking brake lever moves three

notches on the toothed sector when the brake is
engaged.
3. Check that the dashboard warning light (parking

brake engaged light) illuminates when the brake
lever is engaged. 32
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 1
SECTION 35 -- HYDRAULIC SYSTEM
Chapter 1 -- Rear Mechanical Hydraulic Lift

CONTENTS
Operation Description Page

35 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
35 110 40 Lift internal controls, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lift adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
35 110 08 Tie-rod adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Various adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
35 110 42 Lift cylinder and arms shaft, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
35 114 14 Lift control valve (with control valve removed), Disassembly--Assembly . . . . . . . . . . . . . . 36
35 114 30 Lift pressure relief valve, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
35 114 32 Lift pressure relief valve (Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
MAIN SPECIFICATIONS OF REAR MECHANICAL HYDRAULIC LIFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with controlled position/draft and

mixed control
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of two independent
levers
Setting speed of lift reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . automatic, by means of
hydraulic device integral to
control valve
LIFT--O--MATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . allows fast lifting/lowering
operations using push buttons,
without using the draft control
position levers
Single--acting cylinder:
-- rated diameter and stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 95 x 128
(in.) (3.7402 x 5.0393)
-- capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 907
(gal.) (0.240)
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 190 to 195
(psi) (2755.9 to 2828.4)
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 210 to 215
(psi) (3046 to 3118.5)
Lift piston diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 94.980 to 95.000
(in.) (3.7394 to 3.7402)
Internal diameter of cylinder liner: . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 95.036 to 95.071
(in.) (3.7416 to 3.7430)
Clearance between piston and liner . . . . . . . . . . . . . . . . . . . . . . . . mm 0.036 to 0.091
(in.) (0.0014 to 0.0036)
2 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
MAIN SPECIFICATIONS OF REAR MECHANICAL HYDRAULIC LIFT

(continued)
Diameter of arm lifting shaft (5, fig. 4) in relation to bushings:
-- right--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 54.970 to 55.000 (2.1642 to 2.1654)
-- left--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 47.975 to 48.000 (1.8888 to 1.8898)
Internal diameter of bushings fitted on lift body:
-- right--hand side (4, fig. 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 55.100 to 55.184 (1) (2.1693 to 2.1726)
-- left--hand side (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 48.100 to 48.184 (1) (1.8937 to 1.8970)
Clearance between lifting arm shaft and relative right--hand side bushings . . . . . . mm (in.) 0.100 to 0.214 (0.0039 to 0.0084)
Clearance between lifting arm shaft and relative left--hand side bushings . . . . . . . mm (in.) 0.100 to 0.209 (0.0039 to 0.0082)
Interference between bushings and relative seats . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.065 to 0.161 (0.0026 to 0.0063)
Axial clearance of shaft complete with lifting arms . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.2 to 1.4 (0.0079 to 0.0551)
External diameter of draft control transmission shaft . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 21.967 to 22.000 (0.8648 to 0.8661)
Internal diameter of seats in support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 22.020 to 22.072 (0.8669 to 0.8690)
Clearance between transmission shaft and relative seat . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.020 to 0.105 (0.0008 to 0.0041)
Diameter of position control transmission shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 13.973 to 14.000 (0.5501 to 0.5512)
Internal diameter of position control transmission shaft . . . . . . . . . . . . . . . . . . . . . . mm (in.) 14.016 to 14.059 (0.5518 to 0.5535)
Clearance between draft control transmission shaft and position control

transmission shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.016 to 0.086 (0.0006 to 0.0039)
Clearance between control valve block pin (8, fig. 9) and the relative seat
on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.008 to 0.012 (2) (0.0003 to 0.0005)
Clearance between lift control valve (9) and the relative seat on the control
valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.008 to 0.014 (2) (0.0003 to 0.0006)
Check valve return spring (3, fig. 9):
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 25.5 (1.0039)
-- spring length under load of 52 to 56 N (5.28 to 5.72 kg; 11.64 to 12.61 lb.) . . mm (in.) 17.5 (0.6890)
Control valve block pin return spring (5, fig. 9):
-- spring length under load of 31.7 to 35 N (3.23 to 3.57 kg; 7.12 to 7.87 lb.) . . mm (in.) 34 (1.3386)
Control valve return spring (10, fig. 9):
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 44 (1.7323)
-- spring length under load of 103 to 114.7 N (10.5 to 11.7 kg; 23.15 to 25.79 lb.) mm (in.) 29 (1.1417)
Arm descent speed control valve spring (13, fig. 9) Arm descent speed control
valve spring
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 34 (1.3386)
-- spring length under load of 67 to 73 N (6.86 to 7.46 kg; 15.12 to 16.45 lb.) . . mm (in.) 27 (1.0630)
Intervention speed control valve spring (11, fig. 9):
-- spring length under load of 65 to 71 N (1.61 to 1.79 kg; 3.55 to 3.95 lb.) . . . . mm (in.) 11 (0.4331)
(1) Value to be obtained after obtaining interference fit without grinding operations.
(2) During assembly the control valve block pins and control valves are carefully selected so as to obtain the required
clearance.
MAIN SPECIFICATIONS OF IMPLEMENT HITCHING DEVICE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . three--point linkage
Category: 1st and 2nd
Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of lower arms with flex
bar
Maximum lifting load from horizontal arm link ends with
three--point linkage connected to upper hole on to link and full
length of lifting stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 2640
(lb.) 5820
Maximum lifting load with centre of gravity 610 mm (24 in.) from
the lower arm link ends for the full length of lifting stroke (with to
link connected to upper hole on support): . . . . . . . . . . . . . . . . . . . . kg 2295
(lb.) 5059
Flex bar diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.867 to 24.900
(in.) .979 to .980
Axial clearance of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.5 to 5.42
(in.) .059 to .213
TORQUE SETTINGS
Tightening torque
PART Thread
Nm lfb.lb
Lift
Lift intervention speed adjustment cap valve (C1, fig 1) . . . . . . . . . . . -- 54 40
Control valve block pin spring cap (C2) . . . . . . . . . . . . . . . . . . . . . . . . . -- 54 40
Bolts securing control valve block to lift (C3) . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 26 19
Bolts securing union to control valve block (C4) . . . . . . . . . . . . . . . . . . -- 44 32
Check valve return (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . M 24 x 1.5 83 61
Cylinder safety valve (C6) . . . . . . . . . . . . . . . . . . . . . . . . . M 20 x 1.5 83 61
Control valve cap (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 20 x 1.5 54 40
Lift cylinder retaining bolts:
-- front (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14 x 1.5 157 116
-- upper (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 260 192
Bolts securing lift to rear transmission housing (C9) . . . . . . . . . . . . . . M 12 x 1.25 98 72
Control lever quadrant cover stud bolts (C11) . . . . . . . . . . . . . . . . . . . . -- 49 36
Nuts for lever quadrant cover stud bolts (C12) . . . . . . . . . . . . . . . . . . . M 8 x 1.25 25 19
LIFT--O--MATIC control lever quadrant retaining nut (C13) . . . . . . . . . -- 54 40
Lifting arm plate retaining bolts (C14) . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14 x 1.5 142 105
Eccentric pin retaining nuts (C15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 49 36
Eccentric pin seat cap (C16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 83 61
LIFT--O--MATIC control lever retaining bolts (C17) . . . . . . . . . . . . . . . . -- 54 40
Quadrant with arms control pivot cam retaining bolts (C18) . . . . . . . . -- 49 36
Internal lever mechanisms support pin (C19) . . . . . . . . . . . . . . . . . . . . -- 54 40
Implement hitching device
Flex bar seal support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 64 47
Lateral stabiliser strut support retaining bolts ................... M 16 X 1.5 221 163
Pick--up hitch hook support retaining bolts . . . . . . . . . . . . . . . . . . . . . . M 16 X 1.5 221 163
C1 C2 C3 C4
TORQUE SETTINGS
C5
25427 25428
C3 C6
1
HYDRAULIC LIFT TOOLS X 293838 Punch for fitting needle bearings on
draft control link rod.
Warning -- The operations described in this section X 291862 Wrench for cylinder safety valve set-
can only be carried out with ESSENTIAL tools indi- ting ring nut.
cated by an (X).
To work safely and efficiently and obtain the best re- X 291863 Wrench for lift pressure relief setting
sults, it is also necessary to use the recommended ring nut.
X 293865 Protection device for fitting seal on arm
which are to be made according to the drawings inclu-
descent speed control pin.
ded in this manual.
X 292870 Universal pressure control kit.
291359 Hydraulic lift lifting hook. X 290284 Hand pump for valve calibration.
290090 Rotating stand for overhaul opera-
tions. X 290828 Union for cylinder safety valve calibra-
tion.
X 294081 Ring for fitting piston with lift seals.
X 292535 Punch for fitting lift arm shaft seal. X 290824 Union for lift pressure relief valve cali-
bration.
X 293839 Punch for fitting needle bearings on
control valve block control lever bu- X 293982 Union for checking distributor valve
shing. seal.
X 293838 Punch for fitting needle bearings on lo- X 293984 Guard for pilot valve seal.
wer controlled draft lever.
X 294083 Controlled draft setting tool.
X 293838 Punch for fitting needle bearings on
upper controlled draft lever. X 294082 Position and draft control setting tool.
(*)
26626
2
Bracket to be made for hook 291359 or for overhauling lift to rotating stand.
(Mark tool No. 50155 -- measurement in mm).
Make in Aq 42 material -- (*) Area for fixing bore to rotating stand.
27860
3
Adapter to be made for hook 291359.
(Mark tool No. 50163 -- measurement in mm).
Make in Fe 42 C material
Note* (See tool No. 50155)

Cross--sectional view of lift arms drive shaft

1. Right--hand arm. 8. Left--hand arm thrust washer.
2. Right--hand arm thrust washer. 9. Left--hand arm.
3. Right--hand seal.
10. Internal arm.
4. Right--hand bush shaft support (5).
11. Eccentric control position.
5. Lift arm control shaft.
6. Left--hand bush shaft support (5). 12. LIFT--O--MATIC control pin.
7. Left--hand seal. 13. LIFT--O--MATIC control external gear mechanism.
5
Longitudinal cross--sectional view of lift
1. Cylinder sleeve. 3. Lifting piston
2. Control valve block/cylinder connecting pipes.
Longitudinal and cross--sectional views of lift

1. Anti--extrusion seal and ring. 5. Position control transmission shaft.
2. Control valve block arm lever pin. 6. Lever mechanism unit in operation with controlled
position.
3. Control valve block arm lever. 7. Lever mechanism unit in operation with controlled
4. Draft control transmission shaft. position.
254
38
Longitudinal and cross--sectional views of lift

1. Control valve block pin. 4. LIFT--O--MATIC device spring.
2. Control valve block lever pin. 5. LIFT--O--MATIC lever control pin.
3. Contact ball joint between control valve block pin (1) 6. LIFT--O--MATIC external control lever.
and control lever (2).
Draft control device cross--sectional views

C1. Spacer ring and lower lift arm retaining bolt . 3. Draft transmission rod.
G = 1.5 to 5.42 mm (.059 to .213 in.). Flex bar axial clearan- 4. Flex bar.
ce. 5. Spacer.
1. Lever mechanism unit in operation with controlled 6. Seal.
draft. 7. Ball bushing.
2. Lift adjustment rod in operation with controlled draft. 8. Draft transmission lever.
14
13 3
4
25443
12 5
6
11
25444
7
10 9 8
9
Hydraulic lift control valve block cross--sectional views
1. Oil infeed union. 8. Control valve block pin.
2. Check valve ball. 9. Control valve.
3. Check valve return spring. 10. Control valve return spring.
4. Cylinder safety valve. 11. Intervention speed adjustment valve spring.
5. Control valve block pin return spring. 12. Intervention speed adjustment valve.
6. Seal and ring. 13. Arm descent speed adjustment valve spring.
7. Control valve block pin seat. 14. Seal and ring.
NOTE: When fitting seals 6 and 14, heat the corresponding support disks in oil at a temperature of approximate-
ly 50 °C (122 °F).
When fitting seal (14) and its support disk, use protection device 293865.
When fitting seal (6) and its support disk, use protection device 293984.

The mechanical lift can operate with controlled posi- Draft control is performed by the flex bar, positioned
tion and draft, and with mixed control. in the seat mounted in the rear transmission housing
The lift is controlled by two special levers located on the position and draft control levers.
the operator’s right--hand side. It also features the The lower lift arms and corresponding control rods
Lift--O--Matic device which raises and lowers the im- are connected to the flex bar.
plement without having to use.
Discharge oil
Brake circuit oil at rest
Static oil
Intake oil
Delivery oil
10
HYDRAULIC LIFT CIRCUIT
1. Hydraulic pump. 4. Rear auxiliary control valves.

2. Pressure relief valve. 5. Lift hydraulic control valve.
3. Trailer brake valve. 6. Filter.
Discharge oil
Pressurised oil
A
11
ARM LIFT PHASE

A. Detail of operation with controlled position. 4. Check valve.
1. Intervention speed adjustment valve. 5. Draft transmission rod.
2. Arm descent speed control valve. 6. Control valve block pin.
3. Cylinder safety valve. 7. Control valve.
When the operator uses the position control lever (lo- shes on the arm lifting piston.
cated on the right--hand side) to raise the arms, the With controlled draft operation, the lift command is
movement shown by the arrows (detail a) is transmit- sent to the flex bar, which in turn transmits the move-
ted by the internal lever mechanisms to the control ment (shown by the arrows) to the control valve block
valve block pin (6). This pin interrupts the oil flow to pin (6) via the transmission rod (5).
the control valve (7), which is pulled by its spring.
The pressurised oil opens the check valve (4) and pu-
Static oil
Discharge oil
Delivery oil
12
NEUTRAL PHASE
1. Intervention speed adjustment valve. 5. Draft transmission rod.

2. Arm descent speed control valve. 6. Control valve block pin.
3. Cylinder safety valve. 7. Control valve.
4. Check valve.
When the lift arms have reached the predetermined on the control valve piston overcomes the resistance
height, the internal lever mechanisms are stationary. of the spring and moves the valve. This creates a di-
The position of the control valve block pin (6) directs scharge opening and allows the oil to flow to the tran-
the oil to the control valve piston (7). The oil pressure smission casing instead of the lift cylinder.
Discharge oil
Delivery oil
a
13
ARM LOWER PHASE
A. Detail of operation with controlled position. 4. Draft transmission rod.

1. Intervention speed adjustment valve. 5. Control valve block pin.
2. Arm descent speed control valve. 6. Control valve.
3. Check valve. 7. Cylinder safety valve.
When the operator lowers the position control lever With controlled draft operation, the lowering com-
on the right--hand side, the arms are lowered.. The in- mand is sent to the flex bar, which in turn transmits the
ternal lever mechanisms transmit movement (shown movement (shown by the arrows) to the control valve
by the arrows, detail a) to the control valve block pin block pin (6) via the transmission rod (5).
(6). The control valve block pin (6), is pulled down-
ward by its spring, allowing the cylinder of oil, under NOTE: The lowering speed of the implement connected to
the thrust of the piston, to discharge through the arm the lift arms is controlled by the position of the arm descent
descent speed control valve (2) and the outlet created speed control valve (2). Slackening the valve (2) control
by the control valve block pin. The discharge oil pas- screw reduces the size of the outlet between the valve and
ses through the valve (2) and pushes on the control the control valve block body. This means that the implement
valve piston (7). This overcomes the resistance of the takes longer to lower. Fully tightening the screw increases
spring and moves the valve, thereby creating an ou- the size of the discharge opening and the implement lowers
tlet and allowing the oil to flow to the transmission more quickly.
housing instead of the lift cylinder.
HYDRAULIC LIFT TROUBLESHOOTING
The lift does not rise. 1. Oil filter clogged. Replace filter.
2. Control valve jammed in dis- Release control valve.

charge position.
3. Hydraulic pump faulty. Overhaul or replace pump.
The lift moves in jerks. 1. Oil filter clogged. Replace filter.
2. Air in the pump suction line. Check that the unions are airtight
and the seals are efficient.
The lift rises too slowly. 1. Oil filter clogged. Replace filter.
2. Oil leaking past the seals result- Replace all defective seals.
ing in pressure loss: piston
seals or seals on discharge fit-
ting to cylinder.
3. Hydraulic pump faulty. Overhaul or replace pump.
The lift lowers too slowly. 1. Arm descent speed set incor- Set correctly.
rectly.
The lift lowers too quickly. 1. Arm descent speed set incor- Set correctly.
rectly.
HYDRAULIC LIFT TROUBLESHOOTING
(continued)
Problems Possible Causes Solutions
The lift is unable to keep the load 1. Faulty seal on check valve. Dismantle, check and replace the
raised (with the engine running, parts concerned, if necessary.
the load moves up and down
rhythmically; with the engine
turned off, the load lowers). 2. Oil leaking past the seals on Replace the seals.
the control valve block pin
seat.
3. Control valve block pin seal Dismantle and clean the seal; re-
faulty. place the control valve block pin and
seat if defective.
4. Oil leaking past the lift piston Replace the seals.

seal or the seals on the cylin-
der oil discharge fitting.
5. Defective seal or cylinder safety Replace the valve.

valve seal set to very low value.
The pressure relief valve cuts in 1. Lift arm travel set incorrectly. Set correctly.
when the lift arms reach the
completely raised position.
Lift has poor lifting capacity. 1. The pressure relief valve is set Replace the valve.
incorrectly.
2. Cylinder safety set incorrectly. Replace the valve.
3. Poor pump efficiency (gen- Overhaul or replace pump.

erally combined with a con-
siderable increase in lift time).
OP. 35 110 40
LIFT INTERNAL CONTROLS
DISASSEMBLY--ASSEMBLY
(With the lift removed)
DANGER
Do not put your hands or fingers between parts. Wear
suitable safety clothing -- safety goggles, gloves and
shoes.
1
Proceed as follows.
2
1. Position the lift on a rotating stand 290090 using

the bracket 50155 to be made in the workshop
(see fig. 2).
2. Disconnect the connecting pipe (2) between the

auxiliary control valve block (1) and the lift control
valve block, unscrew the retaining bolts and re-
25453
move the auxiliary control valve block (1), re-
covering the O--Ring seal. 14
3. Unscrew the retaining bolts and remove the lift
hydraulic control valve block (1).
1
Rotate the lift holding the relative arms.
25454
15
4. Using a magnetic flexible tool (1) recover the con-
trol valve block pin contact ball (2) making sure
1 2
that it doesn’t drop.
25455
16
5. Remove the front bolts, the rear union and re-
cover the oil delivery pipe (1) to the lift cylinder.
1
25456
17
6. Unscrew the retaining bolts and remove the Lift--
O--Matic device spring (1).
1
25457
18
7. Unscrew the retaining bolts (1), loosen and re-
move the pin (2) and bush, then recover the con- 1
trol valve block lever mechanisms (3).
Unscrew the cylinder retaining bolts and remove.
25458
19
8. Unscrew the retaining nuts and recover the sup-
port cap (1) and spring.
1
NOTE:Apply pressure on the support (1) to prevent

the spring from pressing it against the retaining nut.
25461
20
9. Unscrew and remove the draft control internal

lever pivot eccentric pin (1). 1
25462
21
10. Remove the circlip (4) and recover the washer,
the external lever (3), the relative clutch disks, the
1 2
Woodruff key and extract the draft and position
control internal levers (1 and 2) and shafts from
the inside. 3
4
25463
22
11. Use the striker 293838 (1), to replace the bear-
ings in the internal draft control lever (2). 2
1
26298
12. Use striker 293839, to replace the control valve
block control lever bearings. 23
Assembly
ATTENTION
13. To re--fit the hydraulic lift internal controls, pro-

ceed as follows.
-- Study the illustrations in figs. 4, 5, 6, 7 and 8 for

the positioning of the various parts.
-- Apply the torque settings listed on page 3.
-- Fit the position and draft control internal levers,

complete with: shafts, keys, clutch disks, external
levers, washers and circlip.
-- Tighten the draft control internal lever pivot ec-

centric pin.
-- Fit the spring and cover on the position and draft

control axis and secure the cover with the lock
nuts.
-- Fit the control valve block control lever unit.
-- Fit the cylinder.
-- Fit the Lift--O--Matic device spring.
-- Fit the oil delivery pipe to the lift control cylinder.
-- Fit the control valve pin contact ball.
Carry out the adjustments described below.
NOTE:the adjustments must be carried out in the

order specified.
-- Carefully clean and degrease the mating sur-

faces, then apply sealing compound (approx. 2
mm) along the marked line shown in the drawing.
The types of sealing compound are listed on page
1, Section 00.
Fit the hydraulic lift on the lift box and secure in
position with the relative retaining bolts.
-- Fit the auxiliary control valve block, the O--Ring

27156
seals and the connecting pipe to the lift hydraulic
control valve block. 24
LIFT ADJUSTMENTS
The following adjustments refer to a lift without hy- 1
draulic control valve block and mounted on a rotating
stand.
NOTE:These adjustments must be carried out in the

order specified.
14. Detach the spring (1) in order to exclude the Lift--

O--Matic device.
25470
25
Adjusting controlled position
Proceed as follows. 1
15. Move the external position control lever (2) com-
pletely forward against the spacer for the stud bolt
securing the spring retaining bracket, and the ex-
ternal draft control lever (1) completely back
against the spacer.
16. Turn the arm control shaft so that the internal arm
comes into contact with the lift body.
2
25471
26
17. Position the contact ball (3, fig. 7) in its seat and
attach tool 294082 (1) to the lift body so that it 1
makes contact with the ball.
Rotate the lift through 180° holding the arms.
25472
27
18. Loosen the locknut and totally unscrew the ad-
justment bolt (2), to the end of the lever (1).
1
NOTE:To facilitate this operation, lower the lift arms.

Once the operation has been completed, return the
25473
lift arms to their original position.
28
19. Unscrew the locknut (1) and tighten or slacken
the rod (2). 1
25474
29
20. Check that the cap end (2) on tool 294082 (1) is
at exactly the same external stop face as the tool.
Tighten the locknut (1, fig. 29)
25475
30
21. Move the external position control (1) and draft
control (2) levers completely backwards against
the spacer.
1
25476
31
22. With the lift arms fully lowered, check that the cap
(2) of tool 294082 (1) is either aligned with or fur- 1
ther inside than the internal reference surface on
the tool (1).
2
25477
32
Upper stroke limit adjustment

pletely forward against the spacer for the stud bolt
securing the spring retaining bracket, and the ex-
ternal draft control lever (1) completely back
against the spacer.
24. Turn the arm control shaft until the internal arm is
in contact with the lift body.
2
25471
33
25. Position the contact ball (3, fig. 7) in its seat and
attach tool 294082 (1) to the lift body so that the
tool comes into contact with the ball.
1
Rotate the lift through 180°.
25472
34
26. Tighten the adjustment bolt (2) on the lever (1) un-
til the cap (2, fig. 36) on tool 294082 (1, fig. 36)
1
is aligned with the internal reference surface of
the tool.
NOTE: To facilitate this adjustment bolt (2) tightening

operation, lower the lift arms, then return the lift arms
to their original position to check the position of the 2
cap (2, fig. 36 ) on the tool.
Lock in position using the locknut.
25473
35
2
25477
36
Controlled draft adjustment
Proceed as follows:
1
27. Move the external position control (1) and draft
control (2) levers completely backwards against
the spacer.
2
25476
37
28. Make sure that the milling on the eccentric pin (1)
is in the vertical position.
25478
38
29. Place tool 294083 (2), complete with the end sec-
tion (3) and the draft transmission rod, on a refer-
1
ence plane. Adjust the end section (3) until the rod
on tool(1) is aligned with the tool, providing a mi-
crometer (1) reading of 0.
25479
39
30. Place the tool (2) on the lift body, secure in posi-
tion with the two bolts and fully tighten the screw
1 2
(1).
25480
40
31. Adjust the draft control rod (3, fig. 40) until the
end of the cap (2, fig. 41) on tool 294082 (1) is ex-
actly aligned with, or as near as is possible, to the
external reference surface as the tool.
32. Remove tools 294082 and 294083 from the lift
body, fit the hydraulic control valve block and at-
tach the Lift--O--Matic device spring (1, fig. 1
NO TAG).
Fit the lift on the tractor as follows.
2
25475
41
WARNING -- First position tool 294083 (2) on a refer-

ence surface and use a micrometer depth gauge (1)
to measure the distance (L5) between the point where
the tool rests on the reference surface and the point 1
where the micrometer gauge rests on the tool.
Mark the measured distance (L5) on the tool.
2
L5
25481
42
33. Fit the complete draft measuring device (3), but
without the flex bar, on the rear transmission
1 2
housing.
34. Rest the transmission lever (3) on the transmis-
sion casing and fit tool 294083 (1) on the housing.
35. Use a micrometer depth gauge (2) to measure the
distance (L8) between the top end of the rod (3) L8
and the micrometer gauge resting surface on the
tool 294083 (1). L6
3
25482
43
NOTE: The distance (L6) the top end of the rod (3)
protrudes from the transmission casing (with flex bar
removed) is given by:
L6=L5 - L8
where:
L5 and L6 = distance measured with tool 294083 fitted

on the reference surface (L5, fig. 42) or on the trans-
mission housing (L8).
36. Fit the flex bar in the seat on the rear transmission
casing and, using the micrometer depth gauge
1
(2), measure the distance (L9) between the top
end of the rod (3) and the micrometer gauge rest-
ing surface on the tool 294083 (1). 2
L7 L9
NOTE: The distance (L7) the top end of the rod (3)
protrudes from the transmission casing (with flex bar 3
fitted) is given by:
L7 = L5 - L9
4
25483
where:
44
L5 and L9 = distance measured with tool 294083 fitted
on the reference surface (L5, fig. 42) or on the trans-
mission housing (L9)
37. Check that the distance (L7) is at least 5 mm

greater than the distance (L6).
38. Slacken the locknut (4) and adjust the length of

the draft control rod until it protrudes by a new dis-
tance (L7 = 23.4 to 23.6 mm; 0.9213 to 0.9291
in.).
39. This distance (L7) can be calculated by subtrac-

tion using tool 294083
L10 = L5 -- L7
where:
L7 = 23.4 to 23.6 mm (0.9213 to 0.9291 in.). Dis-

tance the end of the rod (3) protrudes with respect
to the transmission casing.
L5 = distance measured with tool 294083 fitted on

the reference surface.
L10 = distance to be measured with the microme-

ter gauge on the tool 294083.
40. Tighten the locknut (4) and fit the lift on the tractor.
OP. 35 110 08
ROD MECHANISM ADJUSTMENTS
Position control rod adjustments
Proceed as follows:
1. Move the position control lever (1) forward com-

pletely on the quadrant and check that the dis-
tance (L) is 5 to 10 mm (0.1968 to 0.3937 in.). 45
pletely back against the spacer.
1 2
3. Connect the control rod and adjust the length, if
necessary.
4. Secure the rod in position using the locknuts.
25496
46
Draft control rod adjustments
Test conditions:
-- engine running at medium speed;
-- allow the oil in the system to reach a temperature

of 30 to 40 °C (86 to 104 °F).
Then proceed as follows:
5. Move the position control lever (1) forward com-

pletely on the quadrant and the draft control lever
(2) to a distance (L1) of 5 to 10 mm (0.1968 to
0.3937 in.) from the beginning of the slot. 47
6. Move the external draft control lever (2) com-
pletely back against the spacer.
1 2
7. Connect the control rod and adjust the length, if
necessary.
25496
48
8. Move the draft control lever (2) to a distance (L2)
of 103 to 108 mm (4.0551 to 4.2520 in.) from the
beginning of the slot and check that in this posi-
tion the arms start to rise.
9. If the arms do not rise, adjust the eccentric pin (1,

fig. 38) to reset this distance.
10. Lock the pin in position using the locknut.
49
LIFT-O-MATIC device adjustments
Proceed as follows:
11. Move the position control lever (1) and the draft
control lever (2) completely forward on the quad-
rant.
50
12. Raise the arms by means of the lever (1).
1 2
25499
51
13. Tighten the nut (1) until the arms lower.
14. With the lever (1, fig. 51) still in the same position, 1
unscrew the nut (1) until the arms begin to rise.
15. Unscrew the nut (1) by another 1.5 turns.
16. Using the levers (1 and 2, fig. 51) lower and raise
the arms a few times to ensure that the device is
operating correctly.
25500
52
LIFT ARM DESCENT SPEED ADJUSTMENTS

1 2
Test conditions:
-- apply a load of 100 kg (220.5 lb.) to the link ends

of the lower implement attachment arms;
of 50 to 60° C (122 to 140° F).
Proceed as follows.
1. Fully raise the arms. 25501
2. Slacken the locknut (1). 53

3. Lower the arms and, by means of the screw (2),
adjust the lowering speed to a time of 2 to 2.5 sec-
onds (by tightening the screw the time decreases,
by unscrewing the screw the time increases).
4. Tighten the locknut (1), making sure that the
screw remains stationary (2).
UPPER STROKE LIMIT ADJUSTMENT

CHECK
Test conditions:
-- apply a load of 100 kg (220.5 lb.) to the link ends
of the lower implement attachment arms;
of 50 to 60° C (122 to 140° F). 54
Proceed as follows:
1. Move the position and draft control levers (1 and 1
2, fig. 54) completely forwards on the quadrant.
2. Raise the arms (1) until the internal arm comes

2
into contact with the lift body, stamp two corre-
sponding reference marks (2) on the lift body and
the arm.
25503
55
3. Start the engine and, using the position control le-
ver (1, fig, 54), raise the arms (1) and check that
there is a distance of 2 to 4 mm (0.0787 to 0.1574 1
in.) between the reference marks (A).
2
25504
56
OPERATIONS TO BE PERFORMED TO
ADJUST THE UPPER STROKE LIMIT OF
THE LIFT--O--MATIC DEVICE
WARNING
Handle all parts carefully. Do not put your hands or fin-
gers between parts. Wear suitable safety clothing --
safety goggles, gloves and shoes.
WARNING
1
Proceed as follows:
1. Apply a load to the link ends of the lower imple-
ment attachment arms.
2. Start the engine and keep it running at medium
speed.
25505
3. Hold down the push--button (1) until the arms are
in the attachment position (completely lowered). 57
4. Move the levers (1 and 2) completely forward on

the quadrant (completely lowered).
5. Using the position control lever (1) raise the arms
to the desired height.
6. Stop the engine.
7. Press the LIFT--O--MATIC pushbutton (arms rai-
se).
58
8. Slacken the lever (1) and turn the mobile sector
(2) clockwise until it touches the needle (3) on the
LIFT--O--MATIC control lever (4).
9. Use the LIFT--O--MATIC control buttons to raise 1
and lower the arms a few times to ensure correct 2
operation.
NOTE: The arm upward stroke limit only applies to

the LIFT -- O -- MATIC device and does not affect the
other functions of the lift. This means that the arms 3
can be raised completely using the control levers (1
and 2, fig. 58 ).
4
25506
59
OP. 35 110 42
ARM SHAFT AND LIFTING CYLINDER
DISASSEMBLY -- ASSEMBLY
(With the lift removed)
Disassembly
DANGER
Proceed as follows:
1. Remove the front bolts, the rear union and recov- 1

er the oil delivery pipe (1) to the lift cylinder.
2. Remove the three lift cylinder retaining bolts.
25456
60
3. Remove the lift control cylinder (1).
1
25460
61
4. Loosen the nut (4) and recover the locking lever
(3) on the lifting stroke limit cam (1), unscrew the
nut (2) and remove the cam (1).
1
4
25464
62
5. Unscrew the retaining bolt (3) and recover the
thrust washer (2) and the lifting arm(1).
Repeat this operation on both sides.
1
25465 3 2
63
6. Straighten the securing ring and unscrew the re-
taining bolt that secures the ring--cam to the inter- 1
nal arm (1).
25466
64
7. Using a brass drift, strike the end of the shaft (2),
extract the shaft and the internal arm (1), the ring--
cam and the seal (3).
1
2
25467
65
8. Use compressed air to remove the piston (2) from
its cylinder (1). 2
1
26297
66
Assembly
WARNING
To refit the arm shaft and lifting cylinder, proceed as

follows.
-- Study the illustrations in figs. 4, 5 and 6 for the
positioning of the various parts.
-- Apply the torque settings listed on page. 3.
9. Using tool 294081 (2) insert the piston (1) into its
cylinder (3).
1 2
25634
67
10. Fit the lift arm shaft (2), the ring--cam and the in-
ternal arm (1) inside the lift box, matching up the 1
reference marks.
Tighten the bolt that secures the ring--cam to the
internal arm and stake the retaining bolt washer.
2
25468
68
11. To avoid damaging the internal seal lips (2), use
a flexible brass sheet (1) dimensions: 200 x 90
mm (7.8740 x 3.5433 in.) and 0.05 to 0.1 mm
1
(0.0020 to 0.0039 in.). Roll up the sheet and insert
the seal inside. Position the unit on the spline and
push the seal manually into its seat, then remove
the sheet.
2
26300
69
12. Use the striker 292535 (1), to complete the fitting
of the seals into the relative seats on the arm
1
shaft.
26326
70
13. Fit the lift arms (1) on the shaft, matching up the
reference marks. Secure in position with the bolts 1
and washers.
25469
71
14. Fit the lifting stroke limit cam (1), nut (2) and the
relative locking lever (1) and the lock nut (4).
1
25464
72
15. Fit the control cylinder, securing in position with
the three retaining bolts. 1
16. Fit the oil delivery pipe (1) to the control cylinder.
25456
73
OP. 35 114 14
LIFT CONTROL VALVE
DISASSEMBLY -- ASSEMBLY
(with control valve removed)
Disassembly
WARNING
Proceed as follows:
1. Before disassembly, thoroughly clean the sur- 1 2
faces of the control valve block. Lock the control
valve block in a vice, loosen the screws and re-
move the union (1).
2. Unscrew the locknut (2) and recover the spacer 3
(3).
25484
74
3. Remove the cap (1), complete with speed inter-
vention adjustment valve, seat (3), piston (2) and 1 2 3 4
control valve shutter (4).
25485
75
4. Unscrew the cap (2) and remove the control valve
spring (1).
25486
76
5. Remove the cylinder safety valve (4) and recover
the arm lowering speed adjustment valve (3), the
spring (2) and the pin (1).
1 2 3 4
25709
77
6. Unscrew the cap (1) and remove the spring (2),
the control valve block pin (3) and its seat (4). 1 2 3 4
25487
78
7. Remove the check valve, comprising: ball (1),
spring (2) and union (3).
25488
79
8. Check the wear of the seals on the control valve
block--pin seat. If damaged, replace the seals us-
1
ing protection device 293984 (1) and following the
instructions on page 11.
Check the efficiency of the control valve block pin

as follows.
25714
80
9. Fit the control valve block pin (2) complete with

seat (3) on the tool 293982 (1). 1 2 3
25715
81
10. Fit the control valve block pin spring (1) and the
cap (2) of tool 293982. Tighten the cap as far as
it will go and check that the control valve block--
1 2
pin slides in its seat.
25716
82
11. Fit tool 293982 (2) on the hand pump 290284 (3),
filled with HYDROSYSTEM 68 oil. Connect a dial 1
gauge (1), securing in position with the screw.
25717
83
12. Operate the hand pump, whilst tightening the tool
screw (1), until the oil stops flowing out through
the control valve block pin seat outlet.
Zero set the dial gauge.

1
Tighten the screw (1) on the tool further to move

the control valve block pin by 1.8 to 2 mm (0.0709
25718
to 0.0787 in.), using the dial gauge to read this
distance. 84
13. Operate the hand pump until the oil in the system
is at an initial pressure of 245 bar (3553.6 psi). Us-
ing the pressure gauge, check that it takes more
than six seconds for the pressure to fall 196 bar
(2842.9 psi) to 98 bar (1421.4 psi). If it takes less
than this time, replace the control valve block pin.
Bear in mind that this part is supplied together
with the relevant seat.
25719
85
14. Fit the cylinder safety valve (1) on the valve union
290828 (2) and connect to the hand pump 1 2 3
290284 (3).
15. Operate the hand pump (3) and check that the
cylinder safety valve opens at a pressure of 210
to 215 bar (3046 to 3118.4 psi). If the valve setting
does not correspond with the specified value, it is
advised to change the valve immediately. If nec-
essary it can be adjusted by turning the threaded
cap using wrench 291862. Tighten to increase
the valve setting value or loosen to reduce the val-
ue.
Assembly
WARNING
16. To refit the hydraulic control valve block, proceed

as follows:
-- Refer to the instructions on page 11 for the posi-
tioning of the various parts.
page 3.
-- Fit the complete control valve block pin.
-- Fit the check valve. 25720
-- Fit the cylinder safety valve. 86

-- Fit the control valve.
-- Fit the intervention speed adjustment valve.
-- Fit the oil infeed union.
OP. 35 114 30
LIFT PRESSURE RELIEF VALVE REMOVAL -- 1
INSTALLATION
Proceed as follows:
1. Remove the protective guard.
2. Remove the relief valve (1) and, if faulty, replace.
3. Re--position the protective guard.
OP. 35 114 32
LIFT PRESSURE RELIEF VALVE 25507
(SETTING) 87
Proceed as follows:
1. Run the engine until the oil in the system reaches 1
a temperature of approximately 50° C (122° F).
2. Insert the fitting 293449 (1) in a quick--fit female
half--coupling and connect it to the 0 to 245 bar (0
to 3553.6 psi) scale pressure gauge, supplied
with kit 292870.
3. Activate the half--coupling control valve block le-
ver until the pressure relief valve cuts in.
4. With the engine running at medium speed the
pressure gauge must show a pressure of about
186 to 191 bar (2697.8 to 2770.4 psi). If the valve 25508
setting does not correspond with the specified
88
value, it is advised to change the valve immedi-
ately. If necessary it can be adjusted by turning
the threaded cap using wrench 291863. Tighten
to increase the valve setting value or loosen to re-
duce the value.
Chapter 2 -- Open Centre System Auxiliary Control Valves
CONTENTS
35 000 Main data -- Tools -- Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chapter 1
35 204 46 Auxiliary control valves, Disassembly--Assembly (with the unit removed) . . . . . . . . . . . . . . 9

MAIN DATA
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full--flow filter, with
paper cartridge, (common to the
hydraulic lift circuit)
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear pump (common to the

hydraulic lift circuit see Chapter
4).
Auxiliary control valves
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve stack up to a maximum of
4 valves attached to the lift
housing
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (psi) 190 to 195 (2755.9 to 2828.4)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . convertible for operation of single

or double--acting actuators,
convertible for operation of single
or double--acting actuators and
with automatic detent release,
convertible for operation of
double--acting actuators with
float control and automatic
detent release, convertible for
operation of double--acting
actuators with float control.
TOOLS
Warning - The operations described in this section can List of specific tools required for the various opera-
only be carried out with ESSENTIAL tools indicated by tions described in this section.
an (X). To work safely and efficiently and obtain the
best results, it is also necessary to use the recom-
mended specific tools listed below and certain other 292870 Universal pressure testing kit.
tools which are to be made according to the drawings
included in this manual. 293195 Seal guard for Kontak control valve
check valve.
TORQUE SETTINGS
Part Thread Tightening torque
Control valve element locknut 3/8” -- 24 UNF Nm 20.4 kgm 2.1
Front and rear cover retaining bolts 1/4” -- 20 UNC Nm 11 kgm 1
Auxiliary control valve retaining bolts M 10 x 1.25 Nm 59 kgm 6

A B
1 2 3 4 5 6 7 8 9 10 11
27 28 29 30 31
26
25 24 23 22 21 20 19 18 17
25723
1
Auxiliary control valve cross--sectional views (fig. 1-- 2-- 3)
A. Auxiliary control valve configured for operation of 11. Spool.

a double--acting cylinder. 12. Seal.
B. Auxiliary control valve configured for operation of 13. Spring cup.
a single--acting cylinder. 14. Spool return spring.
C. Auxiliary control valve configured for operation 15. Cover.
of a single/double--acting cylinder with float 16. Spacer.
control and automatic detent release. 17. Tapered needle.
D. Auxiliary control valve configured for operation 18. Spring.
of a single/double--acting cylinder with auto- 19. Seal.
matic detent release. 20. Detent balls.
E. Auxiliary control valve configured for operation 21. Seal.
of a single/double--acting cylinder with switch- 22. Seal.
ing float control
23. Internal plunger.
1. Single/double--acting operation switching valve. 24. Spring.
2. Seal. 25. Cover.
3. Valve retaining plug. 26. Detent release pressure adjuster screw.
4. Seal. 27. Spool return spring.
5. Seal. 28. Spring cup.
6. Check valve seat. 29. Seal.
7. Check valve. 30. Detent notch body.
8. Seal. 31. Detent ball support.
9. Seal. 32. Seal.
10. Control support. 33. Seal.
1 2 3 4 5 6 7 8 9 10 11
28 29 30 31
27
26
D
25
24 23 22 21 20 19 18 17
25724
1 2 3 4 5 6 7 8 9 10 11
30 32 33
28
25
24 20 18 17
25725
3
The auxiliary control valves serve for control of hy- Each control lever has three or four positions, de-
draulic loads external to the tractor. pending on the type of control valve it operates.
1. Lifting - Pull the lever towards the operator to ex-

tend the connected cylinder and lift the imple-
ment.
Up to a maximum of 3 auxiliary control valves can be
fitted, on the upper part of the lift housing.
2. Neutral - Push the lever away from the operator,

leaving the lifting position, in order to select the
neutral position and deactivate the connected
cylinder.
The rear auxiliary control valves are operated by the

hand levers located on the right--hand side of the driv-
ing position.
3. Lowering - Push the lever further away from the

operator, beyond the neutral position, to return
the cylinder and lower the implement.
The levers and respective control valves are identi-

fied by colour, as follows:
4. Float (only available on control valve II) - Push
the lever away from the operator, beyond the
”lowering” position to select the ”float position”.
This will allow the cylinder to extend or return
freely, permitting implements (such as blades) to
follow the profile of the terrain.
Lever colour Control valve position/No.

Green RH external -I
Blue RH internal -II
The operation of the hydraulic control valves is de-
Brown RH rear -III scribed on pages 6, 7 and 8.
OPERATING STAGES OF AUXILIARY CONTROL

VALVE FOR THE OPERATION OF A DOUBLE--
ACTING CYLINDER (FIGS. 4 and 5) AND
SINGLE--ACTING CYLINDER (FIGS. 6 and 7)
1. LIFTING - On pulling back the control lever (located

in the cab) the control valve spool (2, fig. 4) shifts
to connect: delivery line (E) with the lower chamber
of the cylinder, by way of the check valve (3) and
the line (G), and also exhaust line (L) by way of line
(H), intercepting the supply of oil to the lift control
valve. Keep the lever pilled back, to extend the cyl-
inder to its full stroke. On releasing the lever it will
automatically return to the neutral position under
the action of the return spring, and the entire flow 4
from the pump will be conveyed to the lift control
valve by way of lines (M).
2. LOWERING - To lower the implement, push the

control lever(located in the cab) forward. The
control valve spool (2) will shift to the position indi-
cated in fig. 5 thus allowing the oil in the lower cyl-
inder chamber to flow to the exhaust (L) through
the line (G), while the upper chamber is con-
nected to the delivery line (E) through line (H) and
check valve (3).
3. LIFTING - On pulling back the control lever (lo-

cated in the cab) the control valve spool (2, fig. 6) 5
shifts to connect the cylinder with the delivery line
(E) by way of the check valve (3) and line (G). Line
(H), for the control of double--acting cylinders, is
not used at this stage as it is permanently con-
nected to the exhaust (L) by the open position of
the switching valve (1).
4. LOWERING - On pushing back the control lever

(located in the cab) the spool (2) will shift to the
position indicated in fig. 7. The oil contained in the
cylinder, pressurised by the weight of the lifted im-
plement, will flow to the exhaust (L) by way of line
(G), while the entire flow from the pump is also
conveyed to the exhaust (L) through the check 6
valve (3) and line (H).
Pressurised oil
Oil in suction, delivery or exhaust
Static oil
Pressurised oil
Static oil
NOTE: For operation of a double--acting cylinder, tight-

en the screw (1). For operation of a single--acting cylin-
der, loosen the screw.
7
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION

OF A SINGLE/DOUBLE--ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE
AND FLOAT POSITION
Pressurised oil
Static oil
8
LIFTING
On pulling back the control lever (located in the cab), psi). Acting through the port (V), it overcomes the re-
the spool (2) shifts and the detent balls (26) engage sistance of the spring of the needle valve (23). Inside
the left hand groove, where they are held in place by chamber (T) the oil pressure increases and, acting on
the support (28) and spring (24). The movement of the detent ball support (28), it overcomes the resist-
the spool (2) connects: delivery line (E) with the lower ance of the spring, thus moving the support (28). In
chamber of the cylinder, by way of the check valve (3) this condition the two detent balls (26) drop onto the
and the line (G), and also the upper cylinder chamber support (28), releasing the spool (2) which, under the
with the exhaust line (L) by way of line (H), intercept- action of the spring (6), returns to the neutral position,
ing the supply of oil to the hydraulic lift control valve. and consequently the entire flow from the pump is
On completion of the lifting movement, the oil pres- conveyed to the lift control valve through lines (M).
sure increases to 170 to 175 bar (2465.8 to 2538.3
9
LOWERING
To lower the implement, push forward the control le- (L) by way of line (G), while the upper chamber is con-
ver (in the cab). The control valve spool (2) shifts and nected with the delivery (E) by way of line (H) and
the detent balls engage in the central groove where check valve (3). On completion of the lowering opera-
they are held in position by the support (28) and the tion, the detent will be automatically released in the
spring (24). In this condition the oil contained in the manner described previously.
lower chamber of the cylinder can flow to the exhaust
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SINGLE/

DOUBLE--ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT POSITION
Static oil
10
FLOAT OPERATION
For float operation push forward the control lever (in the only force exerted on the implement will be that
the cab). The spool (2) shifts and the balls (26) enter created by its own weight, thus allowing the imple-
the right--hand groove, held in place by the support ment to follow the profile of the terrain and permitting
and spring (24). In this position the spool (2) con- the hydraulic lift to be used. With float operation the
nects: the two lines (M) providing the lift control valve automatic detent release function is excluded, as
with the entire pump flow and the two exhaust lines there will be insufficient pressure in the auxiliary con-
(L), by way of lines (H, G) respectively with the upper trol valve.
and lower chambers of the cylinder. In this condition
Single/double--acting switching valve (of con-

trol valve fig. 8 -- 9 -- 10)
1 2 3 4
1. Single/double--acting switching valve.
2. Seal.
3. Valve retaining plug.
4. Seal.
NOTE: For operation of a double--acting cylinder,

tighten the screw (1). For operation of a single--acting
25726
cylinder, loosen the screw.
11
OP. 35 204 46
AUXILIARY CONTROL VALVES
(with the unit removed)
WARNING
WARNING
Convertible single/double acting auxiliary con-

trol valve
Disassemble the auxiliary control valve into its com-
ponent parts, referring to the cross--sectional views
in fig. 1 and the following instructions:
1. Remove the cover (5), recover the spring (4) and 3 4 5

the relative spring cup.
1 2
2. Extract the spool (3).
3. Remove the control lever support (1) and recover
the seal (2).
4. Remove the plug (6) and recover the single/
double action switching valve. 8 7 6
5. Remove the valve housing (8) and recover the
check valve and relative spring.
6. Check the condition of the seals before re--as-
sembly. 24452
12
Single/double--acting auxiliary control valve

with float control and automatic detent release 1 2 3 4
Disassemble the auxiliary control valve into its com-

ponent parts, referring to the cross--sectional views
in fig. 1 and the following instructions:
1. Unscrew the retaining screws, recover the cover

(4) and the spacer (3).
24453
2. Unscrew the retaining screws, recover the con-
trol lever support (1) and relative seal (2). 13
3. Extract the spool (1).

4. Remove the cap (6, see fig. 12) and recover the 1
single/double acting switching valve (7).
5. Remove the valve housing and recover the check
valve and spring.
6. Check the condition of the seals before re--as-
sembly.
Diagram showing the installation of the tools and
equipment required for the spool sticking test for
control valves configured for double--acting op- 24454
eration (fig. 15) and control valves configured
for single--acting operation (fig. 16). 14
Control valve spool sticking test (figs. 15 and 16)
NOTE: With the test equipment filled with HYDRO-

SYSTEM 66 oil, the following tests must be performed
at a temperature of approx. 60°C (150°F) and with a
flow rate of 12.5 litres/min (3.3022 gal./min), which can
be obtained by running the electric motor at the fastest
speed (1450 rpm).
Install the auxiliary control valve assembly and the

test equipment as indicated in the diagrams (figs 15
and 16) and referring to the following instructions:
15
-- on control valves configured for double--acting
operation (fig. 15), the two cylinder delivery ports
must be connected to the ball connector (3) by
way of the pipes (2) and unions (1);
-- on control valves configured for single--acting op-
eration (fig. 16), the return line (2) must be con-
nected, by way of the union (1), to the delivery
port on the control valve (port located opposite to
the switching valve).
After having made the connections as indicated in the
diagram, carry out the test as follows:
16
-- start the hydraulic pump and operate the hand le-
ver to move the spool (in both directions for
double--acting control valves);
-- gradually increase the pressure by turning the
handwheel on the test equipment, checking on
the pressure gauge that the pressure reaches
172 bar (2494.8 psi). In this condition the control
valve spool should slide normally and return to
the neutral position the moment the hand lever is
released;
-- repeat the test on the other control valves after
making the appropriate connections.
Diagram showing the installation of the tools

and equipment required for the control valve
spool leakage test
Valve leakage test
Install the auxiliary control valve stack and the test

equipment as indicated in the diagram (fig. 17) Install
the auxiliary control valve stack and the test equip-
ment as indicated in the diagram.
After having made the connections indicated in the

diagram, carry out the test as follows:
-- start the hydraulic pump and gradually increase 17

the pressure by turning the handwheel on the test
equipment until a pressure of 147 bar (2132.2 psi)
is shown on the pressure gauge;
-- collect the leaked oil flowing from the union (2), in

the burette provided (3) for a period of exactly one
minute. Check that the quantity of oil collected
does not exceed 25 cm3/minute (0.0066 gal./min-
ute) in the case of a new control valve, or 60
cm3/minute (0.0158 gal./minute) for a used valve.
Repeat the test on each control valve, checking alter-

nately the two delivery lines to the user cylinder.
ADJUSTMENT OF THE AUTOMATIC DETENT

RELEASE PRESSURE
Connect the control valve to the test equipment.
Start the hydraulic pump and tighten the release pres-

sure adjuster screw (26, fig. 1) until a pressure of 170
to 175 bar (2465.8 to 2538.3 psi) is obtained in front
of the tapered needle (17).
Lock the screw (26) in position by tightening the lock-

nut.
Chapter 3 -- Trailer Brake Auxiliary Control Valve
CONTENTS
35 000 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cross-sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33 220 40 Trailer brake valve, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The trailer brake valve, which has priority over both The trailer brakes installed on ITALIA versions have
the auxiliary control valves and the hydraulic lift, is the advantage that they brake the trailer even when
mounted on a support and secured on the front right-- the tractor engine is not running, and also when the
hand side of the engine, is controlled by the lift control pump is faulty or produces an inadequate oil flow.
pump. The operation is described on pages 4, 5, 6, and 7.
The hydraulic operation is described on pages 2 and
3.
Cross--sectional view of auxiliary control valve for

trailer braking. (Open--centre circuit).
1. Check valve
2. Pilot valve body.
3. Flow control valve
4. Pilot valve piston.
5. Pressure limiter.
6. Spool.
1
TRAILER BRAKES OFF -- With the trailer brakes off,

the oil from the hydrostatic circuit connected to the
control valve by union (Y) is not pressurised and
therefore the piston (5) of the pilot valve (6) and the
spool (7) are in the rest positions indicated in fig. 2.
The oil from the hydraulic pump arrives at the union

(P1), passing through the diaphragm (1) and the pres-
sure in the restriction (3) drops, thereby causing the
flow control element (2) to shift to the right (2).
The majority of the oil flows through the port (N) to the
auxiliary control valves, while the rest of the oil is dis-
charged to the hydraulic lift through the line (4), the
spool (7) and the port (R).
Pressurised oil
2
Oil in suction, delivery or return
Trailer brakes off.
Static oil N. To the auxiliary control valves.
Tractor brake circuit oil (brakes off) P1. From the hydraulic pump to the lift circuit.
R. To the lift return line.
Pressurised tractor brake circuit oil Y. From the tractor brakes.
START OF BRAKING -- On operating the tractor

brake pedals, the oil of the hydrostatic circuit in port
(Y) is pressurised and thus shifts the piston (7) to the
left, the pressure limiter (6) and the spool (8) which
closes the passage between the oil return port (R),
trailer brake port (B) and the line (5).
The oil inside the flow control valve (4) is maintained

at a uniform pressure, allowing the valve element, un-
der the action of the spring, shifts to the left to assume
the position indicated in fig. 3.
Part of the oil from the hydraulic pump in port (P1)

flows to the auxiliary control valves through port (N),
while the remaining part arrives at the tractor braking 3
element via the diaphragm (2), line (3), check valve
(1) and port (B). Start of braking.
B. To the trailer brake.
N. To the auxiliary control valves.
As the pressure of the oil in the trailer brake port (B) P1. From the hydraulic pump to the lift circuit.
increases, it acts on the active surface (9) of the spool
(8), opposing the pressure applied on piston (7) by R. To the return line in the lift.
the oil in the hydrostatic tractor brake circuit. Y. From the tractor brakes.
BRAKING -- If the driver continues to operate the
tractor brake pedals, the pressure of the oil in the trail-
er brake port (B) increases and acts on the active sur-
face (10) of the spool (9), and overcomes the resist-
ance of the springs (7) of the pressure limiter (8), to
shift the spool to the right.
When the pressure in the trailer brake circuit bal-

ances the pressure exerted by the springs (7), the
spool (9) stabilises in the position indicated in fig. 4
opening the passage connecting the oil from the
pump with the hydraulic lift return line through port
(P1), the diaphragm (2), restriction (5), line (6) and the
port (R).
4
Braking.
B. To the trailer brake.
P1. From the hydraulic pump to the lift circuit.
The diaphragm (2) and the restriction (5) cause a R. To the return line in the lift.
drop in the pressure of the oil circulating in the flow Y. From the tractor brakes.
control valve (4), thus shifting the valve element to the
right to close passage (3) and consequently the
check valve (1).
Pressurised oil
Oil in suction, delivery or return
Static oil
Further pressure on the tractor brake pedals shifts
the piston (7, fig. 3), the pressure limiter(8) and the
Pressurised tractor brake circuit oil
spool (2) to the left, thus causing an increase in the
trailer brake circuit pressure, repeating the stages de-
scribed under the heading START OF BRAKING.
If the pressure in the trailer brake circuit increases as

a result of external causes, the spool (9) shifts rapidly
to open the passage connecting the trailer brake port
(B) and the lift return port (R), thus maintaining a per-
fect balance between the oil pressure in the braking
circuit and the force exerted by the springs (7) of the
pressure limiter.
On releasing the tractor brake pedals, the pressure

in port (Y) drops and the conditions illustrated in fig. 2
are restored.
Oil in suction or delivery

Discharge oil
Tractor brake circuit oil

(brakes off)
Oil at trailer brake release
pressure
5
ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE

(ITALIAN VERSION)
Engine running -- no action on brake pedals
1. Parking brake lever -- 2. Relay -- parking brake warning light circuit -- 3. Relay -- trailer brake circuit -- 4. Trailer brake control
solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b. Return solenoid valve (normally closed) -- 6. Trailer brake
release pressure control valve -- 7. Trailer brake valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -- 9. Hydraulic
pump -- 10. Filter -- 11. Service brake lines -- 12. Delivery lines to auxiliary control valve and hydraulic lift -- 13. Service brakes
pump -- 14. Tractor--trailer coupling -- 15. Trailer brake line -- 16. Trailer brake ”ON” indicator switch -- 17 and 19. Springs --
18. Trailer brake control spool -- 20. Battery -- 21. Parking brake ”ON” indicator switch -- 22. Trailer brake ”ON” warning light.
Oil from the hydraulic pump (9) arrives at the trailer brake valve (7), from where the majority is sent through line (12), to the
auxiliary control valves and the hydraulic lift . A small amount of oil reaches valve (6), where it is discharged in order to maintain
the pressure at a level of 11 to 12 bar (159.5 to 174 psi). Oil at the pressure of 11 to 12 bar (159.5 to 174 psi), flows from the
trailer brake valve through solenoid valve (5a), line (15) and coupling (14) to arrive at the trailer brake. This pressure level is
required to overcome the resistance of the spring (19) and move the relative spring cap. At the same time, spring (17) shifts
the piston (18) to prevent any braking action on the trailer.
Warning -- On starting the engine, in order to reduce the length of time required to bring the circuit up to the pressure
required to release the trailer brake, with the parking brake lever lowered, operate the brake pedals (make sure that
they are linked together). Once the trailer brake is released the warning light (22) will be switched off.
Discharge oil
Oil in tractor brake circuit
(under pressure)
Oil at tractor brake release pressure

(ITALIA VERSION)
Engine running -- brake pedals pressed
A. Line connecting brake pump (13) to trailer brake valve (7) -- 1. Parking brake lever -- 2. Relay -- parking brake warning light
circuit -- 3. Relay -- trailer brake circuit -- 4. Trailer brake control solenoid valves -- 5a. Delivery solenoid valve (normally open)
-- 5b. Return solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer brake valve (see
pages 2 and 3) -- 8. Trailer brake circuit safety switch -- 9. Hydraulic pump -- 10. Filter -- 11. Service brake lines -- 12. Delivery
lines to auxiliary control valve and hydraulic lift -- 13. Service brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake
line -- 16. Trailer brake ”ON” indicator switch -- 17 and 19. Springs -- 18. Trailer brake control spool -- 20. Battery -- 21. Parking
brake ”ON” indicator switch -- 22. Trailer brake ”ON” warning light.
On operating the brake pedals, the pressure generated in line (A), closes the valve(6) return port (R) and consequently the
pressure in the delivery line from the pump (9) increase. The pressurised oil (12 to 150 bar -- 174 to 2175.7 psi) flows out of
the trailer brake valve (7) through line (B) to solenoid valve (5a), which is open, and through line (15) to the trailer brake, where
it overcomes the resistance of the springs (17 and 19) to shift the piston (18) and thus brake the trailer.

Discharge oil
Tractor brake circuit oil
(brakes off)
7

(ITALIA VERSION)
Engine either stopped or running but with insufficient flow from hydraulic pump
pump-- 10. Filter -- 11. Service brake lines -- 12. Delivery lines to auxiliary control valve and hydraulic lift -- 13. Service brakes
When the engine is stopped, or running but with insufficient flow from the hydraulic pump (9), the oil pressure at the trailer brake
valve (7) is either too low or non--existent, and this condition causes the safety switch to close (8). The closure of switch (8)
allows electrical current to energise relay (3), which closes the circuit to the solenoid valves (5a and 5b), thereby closing the
former and opening the latter. In this condition, the oil in the trailer brake and line (15), under the action of spring (19), is dis-
charged through solenoid valve (5b), and the braking action is obtained mechanically by the pressure of spring (19) on piston
(18). The pressure drop caused by the oil discharging allows switch (16) to close and thereby allow current to reach and illumi-
nate warning light (22) on the control panel.
Discharge oil
Tractor brake circuit
oil (brakes off)
8

(ITALIA VERSION)
Engine running -- with parking brake on
pump -- 10. Filter -- 11. Service brake lines -- 12. Delivery lines to auxiliary control valve and hydraulic lift -- 13. Service brakes
On applying the parking brake (1), switch (21) is closed. This allows electrical current to energise relay (2), which closes the
circuit to the solenoid valves (5a and 5b), thereby closing the former and opening the latter. In this condition, the oil in the trailer
brake and line (15), under the action of spring (19), is discharged through solenoid valve (5b), and the braking action is ob-
tained mechanically by the pressure of spring (19) on piston (18). The pressure drop caused by the oil discharging allows
switch (16) to close and thereby allow current to reach and illuminate warning light (22) on the control panel.
Warning -- After applying the parking brake, wait approximately 10 seconds before shutting off the engine, in
order to allow all the oil to be discharged from the trailer brake cylinder and thus obtaining optimum braking.
FUNCTIONAL TESTING AND TROUBLESHOOTING OF TRAILER BRAKE VALVE --

ITALIA VERSION
Test conditions
Oil temperature 40o to 50o C (104o to 122o F). Electrical system powered.
Engine speed: 1000 rpm. Parking brake off.
Trailer brake release pressure test
Proceed as follows:
1. Attach union 293190 (1) to the trailer brake and

connect to the pressure gauge with scale 0 to 40
bar (0 to 565.7 psi), from kit 292870.
2. With the engine running at the prescribed speed

and the oil at the prescribed temperature, the
pressure should be 11 to 12 bar (159.5 to 174 psi).
3. Check that the warning light (22, fig. 8) is not illu-

minated.
25751
4. Apply the parking brake and disconnect the pres-
sure gauge and union 293190 (1). 9
TROUBLESHOOTING
Trailer brake release pressure = 1. Parking brake(1, fig. 8)on. Release parking brake.
0 bar (0 psi) (warning light 22, fig.
8 illuminated).
2. Trailer brake release pressure Replace the valve.
control valve (6) incorrectly ad-
justed.
3. Trailer brake circuit safety Replace switch.
switch (8) faulty.
4. Hydraulic pump (9) faulty. Overhaul or replace hydraulic
pump.
5. Delivery line solenoid valve (5a) Free or replace the solenoid valve.
locked in closed position.
6. Discharge line solenoid valve Free or replace the solenoid valve.
(5b) locked in open position.
Trailer brake release pressure 0 1. Trailer brake release pressure Replace the valve.
to 11 bar (0 to 174 psi). control valve (6) incorrectly ad-
justed.
Trailer brake release pressure 1. Trailer brake warning light Replace switch.
correct, but warning light (22) switch (16) faulty.
illuminated.
Trailer brake release pressure 1. Warning light (22) bulb faulty. Replace bulb.
incorrect, but warning light(22)
not illuminated.
2. Trailer brake warning light Replace switch.
switch (16) faulty.
NOTE: The switch (8) can be identified by the red paint mark between the two terminals.
Testing the setting of the trailer brake system pressure control valve incorporated in the trailer
brake control valve
Proceed as follows:
1. Insert union 293190 (1) to the trailer brake cou-
pling, connect to the pressure gauge with 0 to 245
bar (0 to 3553.6 psi) from kit 292870.
2. With the engine and the oil in the test conditions
described at the beginning of the chapter, apply
a force of 30 to 35 daN (417.7 to 487.4 psi) to the
service brake pedals; the pressure reading on the
gauge should be 135 to 145 bar (1958.1 to 2103.2
psi).
sure gauge and union 293190 (1).
25751
10
TROUBLESHOOTING
Pressure above or below 1. Pressure control valve (6, fig. Replace trailer brake control
prescribed range. 8) of trailer brake system faulty. valve.
2. Hydraulic pump (9) faulty. Replace the pump.
Testing the hydraulic system for leakage
Proceed as follows:
pling, connect to the pressure gauge with scale 0
to 245 bar (0 to 3553.6 psi) from kit 292870.
described at the beginning of the chapter, apply
a force of 30 to 35 daN (417.7 to 487.4 psi) to the
service brake pedals; the pressure reading on the
gauge should be 135 to 145 bar (1958.1 to 2103.2
psi).
sure gauge and union 293190 (1).
25751
11
TROUBLESHOOTING
On applying the prescribed force 1. Oil leaks in the hydraulic sys- Find and eliminate the leaks.
on the service brake pedals, tem.
there are an excessive number of
pressure peaks over a 10 second
period.
2. Excessive leakage from the so- Replace solenoid valve .
lenoid valve (5b, fig. 8).
3. Excessive leakage from trailer replace trailer brake control valve.
brake control valve (7).
Checking that trailer brake release pressure is nullified when the parking brake is applied
Proceed as follows:
to 39.2 bar (0 to 568.6 psi) from kit 292870.
described at the beginning of the chapter, pull the
parking brake lever(1, fig. 8) fully upwards.
3. Check that the pressure is 0 bar and that warning
light (22, fig. 8) is illuminated.
4. With the parking brake applied, disconnect the
pressure gauge and coupling 293190 (1).
25751
12
TROUBLESHOOTING
When the parking brake is 1. Parking brake switch (21, fig. 8) Replace switch.
applied the trailer brake release faulty.
pressure is not nullified.
2. Parking brake indicator relay Replace the relay.
(2) faulty.
3. Discharge line solenoid valve Free or replace the solenoid valve.
(5b) locked in closed position or
faulty.
Controlling the switches (8 and 16, fig. 8)
Proceed as follows:
to 39.2 bar (0 to 568.6 psi) from kit 292870.
2. Without applying the service and parking brakes,
operate the control lever of an auxiliary control
(until the corresponding pressure relief valve is
activated), hold this position for a few seconds
then suddenly release the control lever.
3. Check that the parking brake release pressure re-
mains at the prescribed level of: 11 to 12 bar
(159.5 to 174 psi).
25751
sure gauge and the coupling 293190 (1). 13
TROUBLESHOOTING
On carrying out the operation 1. Trailer brake circuit safety Replace switch.
described above, the trailer brake switch (8, fig. 8) setting higher
release pressure is nullified than the nominal pressure (3 to
permanently. ± 0.5 bar; 43.5 to ± 7.2 psi).
2. Switches (8 and 16) installed in Install the two switches in their
incorrect positions, or electrical correct positions or swap over the
leads connected incorrectly. electrical power leads.
NOTE: The switch (8) can be identified by the red paint mark between the two terminals.
OP. 33 220 40
TRAILER BRAKE VALVE
Removal
WARNING
1. Position a container (3) to collect the oil dis-

charged from the system pipes.
2. Disconnect the pipes (1) connected to the trailer

brake valve.
3. Remove the two trailer brake valve retaining bolts 27890
(2). 14
4. Disconnect the trailer brake valve (1).
Installation
WARNING
Proceed as follows:
27891
5. Fit the trailer brake valve (1, fig. 15) and secure 15
in position with the two retaining bolts (3, fig. 14),
refit the pipes (2) connected to the valve and re-
move the container (1).
Chapter 4 -- Non--Stop Flow Gear Pump
CONTENTS
35 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings -- Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chapter 1
35 104 30 Lift circuit hydraulic pump, Disassembly--Assembly (with unit removed) . . . . . . . . . . . . . . . . 4
MAIN SPECIFICATIONS OF HYDRAULIC PUMP C 42

Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from
rear transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on right--hand side of engine

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C 42
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by engine shaft
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.08
Maximum speed of rotation (with engine at maximum
power 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 2484
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . dm3/min (gaI./min) 47.36 (12.51)
Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (gaI./min) 19.06 (5.04)
Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . mm (inches) 17.400 to 17.418
(0.6850 to 0.6857)
Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . mm (inches) 17.450 to 17.475
(0.6870 to 0.6880)
Clearance between gear shafts and seats on supports . . . . . . mm (inches) 0.032 to 0.075
(0.0013 to 0.0030)
-- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . mm (inches) 0.1 (0.0039)
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . mm (inches) 0.020 to 0.064
(0.0008 to 0.0025)
Maximum wear on pump body, suction side,
at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (inches) 0.1 (0.0039)
Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (inches) 30.800 to 30.815
(1.2126 to 1.2132)
Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (inches) 24.490 to 24.510
(0.9642 to 0.9650)
Width of pump body for gear seats and supports . . . . . . . . . . . mm (inches) 79.935 to 79.960
(3.1470 to 3.1480)
Axial clearance of gears complete with supports
in pump body, (recondition if necessary) . . . . . . . . . . . . . . . . . . mm (inches) 0.100 tp 0.180
(0.0039 to 0.0071)
MAIN SPECIFICATIONS OF BOSCH 25 HYDRAULIC PUMP

rear transmission casing.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH 25
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by engine shaft
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise

Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.08
Maximum speed of rotation (with engine at maximum
power 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 2484
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (gaI./min) 63.84 (16.96)
Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (gaI./min) 25.7 (6.79)
Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full--flow, with replaceable
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on pump intake
Tightening torque
PART Thread
Nm lfb.lb
Pump control coupling hub locknut . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 20 UNF 29 22
The front hydraulic pump serves the hydraulic lift, the They are fitted on the right hand engine support and are
trailer brake valve and the auxiliary control valves. driven by a shaft gear unit.
The different types of pump shown above are of the The oil is taken from the rear transmission casing, pas-
gear type with spur gears and function with non--stop sing through a filter.
flow according to the engine rpm.
25719
Components of C 42 pumps, BOSCH 25

1. Nut. 8. Driven and driving gear shafts.
2. Safety washer. 9. Gear support.
3. Circlip.
10. Pump body.
4. Driving shaft seal.
11. Front cover.
5. Control side cover.
6. Cover seals. 12. Safety washer.
7. Gear support. 13. Bolt.
PUMP MODELS C 42, BOSCH 25

OP. 35 104 30
LIFT OIL PUMP
(with pump removed)
Disassembly
2
WARNING
25227
1. Remove the cover retaining bolts (13, fig. 1) and Assembly
the relative safety washers (12).
2. Remove the nut (1) that secures the sleeve to the WARNING
pump driving shaft and the safety washer (2). Always use appropriate tools to align fixing holes. NE-
VER USE YOUR FINGERS OR HANDS.
3. Remove the front cover (5), the circlip (3) and the
seal (4).
4. Mark the parts (7, 8, 9 and 10), in order to re--fit

them in the same position, if in good condition. 12. To re--fit the pump carry out operations 1 to 6 in
5. Remove the supports (7 and 9) and gears (8) from reverse order, referring to fig. 1 , proceeding as
the front cover (5) and the pump body (10). follows:
6. Recover the seals (6) and the anti--extrusion -- always ensure maximum cleanliness to prevent
rings. foreign matter from entering and damaging the
pump;
Once the parts are removed, proceed as fol-
lows:
-- fit together the previously marked parts (10, 7, 8
7. Check that the gear contact surfaces are flat and and 9), referring to operation 4, in the original po-
perpendicular to their supports. Interpose a thin sitions;
layer of carbon black. Small rough spots can be
removed using extremely fine and adequately lu- -- mount the gear supports (7 and 9) in the pump bo-
bricated abrasive paper. dy, positioning as shown in fig. 1;
8. Check that the axial play of the gear--support unit
in the pump body is 0.100 to 0.180 mm (0.0039
to 0.0071 in.). The distance (2, fig. 2) must be -- insert the plastic anti--extrusion rings on the seals
0.100 to 0.180 mm (0.0039 to 0.0071 in.) less (6);
than the distance (1).
If necessary, true the flat surfaces involved using lu- -- mount the seals (4), on the control side cover (5)
bricated abrasive paper to remove extremely small facing towards the inside;
quantities of material.
9. Clean all constituent parts thoroughly. -- fit the covers (5) and (11), position the washers
10. Replace the seals (4 and 6). (12) and tighten the retaining bolts (13);
11. Lubricate the parts with the same oil used in the
system. -- fit the washer (2) and the locknut (1).
SECTION 41 -- STEERING -- CHAPTER 1 1
SECTION 41 -- STEERING
Chapter 1 -- Steering
CONTENTS
41 000 Torque settings main data -- tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 204 10 Hydrostatic steering wheel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
41 204 30 Hydrostatic steering control valve, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . 10
41 204 34 Hydrostatic steering control valve, (removed) Disassembly -- Assembly . . . . . . . . . . 15
41 204 38 Hydrostatic steering control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 SECTION 41 -- STEERING -- CHAPTER 1
MAIN DATA
HYDROSTATIC STEERING
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . independent hydrostatic control,
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fed by services hydraulic pump
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . paper cartridge on pump intake

side
Control valve, manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DANFOSS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ORBITROL, with the rotating

valve controlled directly by the
steering column; the steering
continues to function even if the
pump is damaged
Outfit code:
Two and four wheel drive models . . . . . . . . . . . . . . . . . . . . . . . . . . OSPC 80 ON -- 150 N 1058
Pressure relief valve calibration (24, fig. 2) . . . . . . . . . . . . . . . . . . . bar 165 to 170

(psi) (2393.2 to 2465.8)
Cylinder safety valve calibration (33, fig. 2) . . . . . . . . . . . . . . . . . . . bar 230 to 240

(psi) (3336 to 3481.1)
TORQUE SETTINGS
Tightening torque
PART Thread
Nm kgm
Bolt securing cover to hydrostatic steering housing (21, fig. 4) . . . . . . M8x1 24 to 36 2.5 to 3.7
Steering column flange retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8x1 23 2.40
Bolt securing hydrostatic steering to tractor . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.5 44 4.5
Hydrostatic steering control pump retaining bolt . . . . . . . . . . . . . . . . . . M6x1 8 0.8
Nut for pump housing cover retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 39 4
Nut for securing thrust sleeve to pump drive shaft . . . . . . . . . . . . . . . . 7/16”--20UNF

--2B 28 2.8
TOOLS

cated by an (X).
OPERATION
Neutral position
When the steering wheel (V, fig. 2) is not moving, the
rotating valve (5) is located in the neutral position in
relation to the sleeve (6). In this position, retained by
springs (2, sect. A--A), the following occurs:
-- the pin (1, sect. B--B) will be in the central position
in relation to the holes on the valve (5);
-- the ducts (13 and 14) are aligned (sect. C--C) and
the oil, from the pump (P), flows freely to and from the
reservoir;
-- the grooves (15, 17 and 19) on valve (sect. D--D,
E--E) are not aligned with the ducts (16,18 and 20) on
the sleeve, therefore all connecting lines with the cyl-
inder remain closed (See diagrams A and d, fig. 2
and 3).
Right--hand steering control
B, R--ht, e, f, (see figure 2 and 3).
By turning the steering wheel (V) clockwise, the
springs (2, sect. A--A) allowing the valve (5) to rotate
in relation to the sleeve (6), until the clearance G1 is
recovered (sect. B--B).
Under these conditions the following occurs:
-- the ducts are not aligned (13 and 14, sect. C--C),
therefore the oil discharge flow is interrupted;
-- the six grooves are aligned (15, sect. D--D) with the
same number of ducts (16), that are connected with
the compartments on the rotor in the suction phase;
-- the six delivery grooves are aligned (17, sect. E--E)
with the ducts (18) connected to the cylinder and, at
the same time, the grooves are aligned with the re-
maining ducts (16, sect. D--D), that are connected
with the compartments on the rotor in the delivery
phase;
-- the alignment of the six discharge grooves (19) with
the ducts (20, sect. E--E) connecting to the cylinder.
Once the clearance (G1) has been recovered, the
valve (5) rigidly transmits the steering wheel rotation
to the sleeve (6) and rotor (9, fig. 2), by means of the
pin (9, fig 4) and shaft (11).
The details (e, f, fig. 3), illustrate how the mechanism
operates at the start of a turn to the right and after a
certain number of steering wheel rotations.
Note that there is an uninterrupted connection be-
tween the oil from the pump with the compartments
on the rotor in the suction phase (and with oil when
the compartments on the rotor are in the delivery
phase) and the relative duct connected to the cylin-
der.
15714
1
Hydrostatic steering operation sectional view
a. Cross--sectional views with the valve (5) in the neutral position -- b. Cross--sectional views with the valve (5) rotated for a right--hand turn
(for a left--hand turn, the valve rotates symmetrically in the opposite direction) -- G1 and G2. Clearance between the pin (1) and the hole on valve
(5) --1. Sleeve trim pin (6) and shaft (11, fig. 4) -- 2. Sleeve return spring (6) -- 5. Rotating valve -- 6. Valve seat sleeve (5) -- 13 and 14. Oil flow
ducts in the neutral position -- 15. Delivery grooves ( n.6) to the compartments on the rotor in the suction phase -- 16. Ducts (n.12) that are alter-
nately connected to the grooves (15 and 17) -- 17. Delivery grooves (n.6) to the cylinder connected to the compartments on the rotor in the
delivery phase and ducts (18 and 20) -- 18. Right--hand cylinder chamber delivery or discharge ducts (n.6) -- 19. Discharge grooves (n.6) cylinder
connected to ducts (18 and 20) -- 20. Left--hand cylinder chamber delivery or discharge ducts (n.6) -- 22. Feed ducts for grooves (15).
Sd
Ss
Delivery oil to control cylinder

Delivery oil to rotor
Intake oil, low pressure delivery or discharge
Static rest oil Ses
Sed
C
2
Left--hand steering control
(B, L--ht, fig. 2)
By turning the steering wheel in a counter--clockwise direc-
tion, the movement of the parts is inverted, the delivery
grooves (17,sect. E--E, fig. 1) direct the oil to the ducts (20),
and control the left--hand turning action.
Emergency hydraulic control
(C, Er--ht, El--ht, fig. 2)
In the event of feed faults, steering is still possible by turning
the steering wheel. The valve (5) remains in the same posi-
tion as with normal control and the rotor works in the same
way as a hand pump, directing the oil to the control circuit.
The non--return valve (4) opens and cuts off the feed pump,
allowing the oil to flow directly from the rotor reservoir.
The valve (23) remains closed in order to prevent oil leaks
from faulty connecting pipes between the hydraulic pump
and the hydrostatic steering unit.
Cylinder safety valve and backflow valve
(see, fig. 2)
The safety valves (33), when open, discharge the pressure
created by the piston (H) on one of the cylinder chambers
as a result of the strong external stress on the wheels.. At
the same time, the lack of pressure in the opposite chamber
is compensated by the flow of oil from the open backflow
valve (34). Pressure on one of the cylinder chambers
caused by weak external stress, insufficient to open the cyl-
inder safety valve, is discharged by means of normal control
valve leakage, whereas the lack of pressure in the opposite
chamber is compensated by the backflow valve (34), as
shown in fig. 2. This valve, as well as eliminating continuous
steering corrections, prevents vibrations on front wheels
(shimmy), hydraulic circuit failure and steering rod distor-
tion.
3
Hydrostatic steering operation circuit sectional view (*see fig. 1)
A. Neutral position operation diagram. 4. Non--return valve.
B. Right--hand turn (R--ht) and left--hand turn (L--ht) operation dia- 5. Rotating valve.
gram. 6. Valve seat sleeve (5).
C. Emergency right--hand turn (Er--ht) and emergency left--hand 9. Rotor.
turn (El--ht) operation diagram. 13 and 14. Oil flow ducts in the neutral position.
d. Operation diagram for sections D--D and E--E in neutral condi- 15. Delivery grooves (n. 6) to the compartments on the rotor in the
tions *. suction phase.
D. DANFOSS OSPC control valve. 16. Ducts (n.12) alternately connecting with the grooves (15 and 17).
e, f. Operation diagrams for sections D--D and E--E in two successi- 17. Delivery grooves (n.6) to the cylinder connecting with the com-
ve right--hand turn phases *. partments on the rotor in the delivery phase and the ducts (18
F. Filter. and 20)*.
H. Control cylinder. 19. Discharge grooves (n.6) to the cylinder connecting with the
M. Pump delivery. ducts (18 and 20)*.
N. Backflow valves (34) operation diagram with control valve (D) in 21. Ducts connecting the holes (16) with the compartments on the
neutral and cylinder (H) piston under external stress (indicated rotor in suction delivery phases
by the black arrow). 23. Non--return valve.
P. Pump. 24. Pressure relief valve (calibration: page 2).
R. Flow control. 26. Left--hand cylinder chamber connecting duct.
S. Discharge to gearbox. 27. Right--hand cylinder chamber connecting duct.
V. Steering wheel. 33. Cylinder safety valve (calibration: page 2).
Z. Resonance attenuator filter. 34. Backflow valve.
27852 4
Hydrostatic steering control valve components

1. Dust seal. 15. Rotor and fixed ring for rotor.
2. Control valve body, rotating valve and rotating valve 16. O--ring seals.
seat sleeve. 17. Cover.
3. Non--return valve ball. 18. Washers.
4. Non--return valve threaded plug. 20. Non--return valve seat screw.
5. VARISEALseal. 21. Cover retaining screws.
7. Thrust bearing components. 24. Pressure relief valve.
8. Retaining ring for springs (12). 25. Pressure relief valve spring.
9. Rotor drive shaft -- sleeve trim pin. 26. Cylinder safety valve.
11. Rotor drive shaft. 27. Backflow valve balls.
12. Springs for returning sleeve to neutral position. 28. Backflow valve springs.
13. O--ring seal. 29. Backflow valve pins.
14. Thrust washer.
HYDROSTATIC STEERING TROUBLESHOOTING
Oil leaking from the hydrostatic 1. VARISEAL seals (5, fig. 4) Replace the seal using tool293955.
steering unit: faulty.
a. Control side.
b. Cover side.
2. Bolts (21) insufficiently tight- Tighten the bolts to the prescribed
ened (21). torque (24 to 36 Nm -- 2.5 to 3.7 kgm).
3. Sealing washers (18) or O-- Replace the washers and seals.
ring seals (16) faulty.
Steering wheel excessively stiff. 1. Hydraulic pump faulty. Repair the pump.
2. Non--return valve (3) held Eliminate foreign bodies and clean
open by foreign bodies or due filter; place a new ball in the seat (if
to absence of ball. missing).
3. Pressure relief valve (24) in- Set the valve correctly.
correctly set.
4. Pressure relief valve (24) Eliminate foreign bodies and clean
jammed or held open by for- filter.
eign bodies.
5. Steering column stiffens on its Eliminate the causes.
bushing due to rust, seizure,
etc.
Excessive steering wheel play. 1. Excessive play between the Replace the hydrostatic steering
steering column and the cou- control valve.
pling with the rotating valve (5,
fig. 2)
2. Excessive play in the coupling Replace the hydrostatic steering
between the shaft (11, fig. 4) control valve.
and the trim pin (9).
3. Excessive play in the splined Replace the hydrostatic steering
coupling between the shaft control valve.
(11) and the rotor (15).
4. Combination of excessive Replace the hydrostatic steering
play as described in the pre- control valve.
vious points.
5. Leaf springs (12) damaged or Replace springs.
fatigued.
The steering wheel turns 1. Inadequate control cylinder Replace the seal.
normally, but the steering is: seal.
a. Slow. 2. Cylinder rod broken. Replace the damaged part.
b. Null. 3. Rotor drive shaft (11) or pin (9) Replace the damaged part.
damaged.
With the engine stopped, the 1. Excessive wear between rotor Replace the hydrostatic steering
steering wheel can be turned and fixed ring (15). control valve.
without turning the wheels.
2. Non--return valve damaged. Replace the hydrostatic steering
control valve.
3. Cylinder safety valve (26) held Eliminate foreign bodies and clean
open by foreign bodies or filter or replace the control valve.
damaged.
HYDROSTATIC STEERING TROUBLESHOOTING
(continued)
Steering wheel jolts, 1. Incorrect synchronisation of Synchronise correctly.

uncontrollable steering, wheels hydrostatic steering.
turning in the opposite direction 2. Pipes to cylinder inverted. Connect correctly.
to that desired.
The wheels do not maintain the 1. Hydraulic cylinder piston seal Replace the seal.
desired alignment and steering worn.
must be continually corrected 2. Cylinder safety valve (26, Eliminate foreign bodies and clean
with the steering wheel. fig. 4) or backflow valves (27, filter or replace the control valve.
28, 29) held open by foreign
bodies or damaged.
3. Control valve mechanical Replace the control valve.
wear.
Neutral phase of hydrostatic 1. Leaf springs (12), for sleeve Replace the leaf springs assembly.
steering unobtainable. (2) return to neutral position,
During manual control, operation damaged or fatigued.
is normal; when stopping manual 2. Sleeve and rotating valve (2) Eliminate foreign bodies and clean
control the steering wheel tends locked in delivery position be- filter.
to move on its own, or remain cause of the presence of for-
stationary, but steering continues eign bodies.
slowly in the direction that was 3. Sleeve (2) crushed on the ro- Check the pressure relief valve
initially selected (motoring), tating valve due to excessive calibration (24, fig. 4).
therefore steering must be pressure.
continually corrected with the
steering wheel.
Vibrations on front wheels 1. Air pockets in the hydraulic Bleed the air and eliminate the
(shimmy). cylinder. causes of possible infiltration.
2. Wear on mechanical joints on Replace the worn parts.
steering rods.
3. Cylinder safety valve (26) or Eliminate foreign bodies and clean
backflow valves (27, 28, 29) filter or replace the control valve.
held open by foreign bodies or
damaged.
Difficulty in steering in general, or 1. Insufficient pressure. Check the hydraulic pump and the
only in one direction. pressure relief valve calibration (24,
fig. 4).
2. Excessive leakage inside the Replace the control valve.
control valve.
3. Cylinder safety valve (26) in- Eliminate foreign bodies and clean
correctly calibrated or soiled filter or replace the control valve.
with deposits that interfere
with the seal of one of the two
valves.
Op. 41 204 10
HYDROSTATIC STEERING WHEEL
(Replacement)
WARNING
Proceed as follows.
1. Using a suitable tool, remove the NEW HOL-

LAND symbol at the centre of the steering wheel,
unscrew the nut and the central knob (1). 5
2. Remove the steering wheel retaining nut and, us-

ing tool 291182 (1), remove the steering wheel.
WARNING
3. To re--fit the steering wheel on the column, pro-

ceed as follows:
4. Position the steering wheel on the column and se-

6
cure with the nut.
5. Fit the knob with the NEW HOLLAND symbol at

the centre of the steering wheel.
Op. 41 204 30
HYDROSTATIC STEERING CONTROL
VALVE
WARNING
To remove the hydrostatic steering control valve, pro-

ceed as follows:


3. Carry out operation 41 204 10: Hydrostatic steer-

ing wheel, only removal (see page 9).
4. Carry out operation 55 418 10: Multi--indicator

panel, only removal (see section 55, chapter 6).
5. Unscrew the instrument panel upper guard (1)

screws. 7
6. Remove the steering column dust guard (1).
8
7. Loosen the screw and detach the hand throttle
control lever grip (1).
9
8. Remove the fuse box cover, unscrew the retain-
ing bolts and remove the fuse box (1).
10
9. Unscrew the indicator lights switch ring nut (1).
11
10. Loosen the retaining screw and remove the lights
switch knob (1).
12
11. Unscrew the lights switch locknut (1) and the
starter ring nut (2).
13
12. Detach the electrical connections and remove the
instrument panel upper guard (1).
14
13. Unscrew the retaining bolts and remove the lower
guard (1). (On both sides).
15
14. Remove the stop ring and remove the hand
throttle lever (1) from the plate (2).
16
15. Remove the spring (1) and extract the pin (2) to
free the brake control pedal (carry out for both
brake pedals).
17
16. Disconnect the four pipes on the hydrostatic
steering control valve.
18
17. Unscrew the hydrostatic steering control and col-
umn (1) retaining screws and remove the steering
column.
19
18. Remove the hydrostatic steering control (1).
19. To re--fit the hydrostatic steering control valve,
proceed as follows:
WARNING
-- Place the hydrostatic steering control valve in

position.
-- Position and secure the steering column.
-- Connect the hydrostatic steering control valve
piping. 20
-- Connect the brake pump and pedals.
-- Connect the throttle lever.
-- Fit the two lower guards.
-- Connect the electrical connections and position
the upper guard.
-- Tighten: the starter and lights switch ring nuts.
-- Assemble and secure the lights switch knob. -- Carry out operation 55 418 10: Multi--indicator
panel, only installation (see section 55, chapter
-- Tighten the indicator lights switch ring nut. 7).
-- Position the fuse box, secure and fit the cover. -- Carry out operation 41 204 10: Hydrostatic steer-
ing wheel, only installation (see page 9).
-- Assemble and secure the throttle lever handgrip. -- Carry out operation 90 100 84: Bonnet guard,
only installation (see section 90).
-- Fit the dust guard.
-- Carry out operation 90 100 22: Bonnet open-
-- Fit the upper guard. ing,only installation (see section 90).
Op. 41 204 34
HYDROSTATIC STEERING
CONTROL VALVE
(with control valve removed)
To disassemble the hydrostatic steering control

valve, proceed as follows:
WARNING
21
1. Remove the retaining bolts cover.
2. Remove the cover by sliding to the side.
24702
22
3. Remove the rotor fixed ring, the rotor and the in-
side spacer.
4. Remove the two O--ring seals on the rotor fixed
ring.
24703
23
5. Extract the rotor drive shaft.
24704
24
6. Extract the thrust washer.
24705
25
7. Remove the threaded plug on the non--return
valve seat.
24706
26
8. Extract the O--ring seal from the control valve
body.
24707
27
9. Rotate the control valve body and extract the
non--return valve ball, the two balls with the rela-
tive pins and the backflow valve springs.
27856
28
10. Position the control valve body and the rotor drive
shaft so that the sleeve--control shaft trim pin is
in a horizontal position.
24709
11. Push the rotating valve inwards, so that the valve,
the valve seat sleeve and the thrust bearing can 29
be extracted from the control valve body.
12. Extract the thrust bearing from the rotating valve,
complete with the two external rings, and remove
the spring retaining ring from the valve seat
sleeve.
24710
30
13. Extract the valve--sleeve trim pin.
24711
31
Warning -- On assembly, two reference marks were

made on the rotating valve and the sleeve, corre-
sponding to the neutral position maintained by the
springs. Before removing the springs, check that the
marks are clearly visible, otherwise renew them.
24712
32
14. Extract the rotating valve from the valve seat
sleeve.
24713
33
15. Remove the springs from the neutral position,
extracting them from their seats.
24714
34
16. Remove the dust seal and the O--ring seal from
their seats on the control valve body.
20428
35
17. Using a 6 mm (0.2362 in.) Allen wrench, remove
the threaded plugs from the cylinder safety
valves.
20429
36
18. Remove the seal washers.
27857
37
the threaded plugs from the cylinder safety
valves.
27858
38
20. Turn the control valve body over, extract the
springs and the balls from the two cylinder safety
valves.
20432
39
Cylinder safety valves components (order of disas-
sembly--assembly).
1. Cylinder safety valve ball. 1 2 3 4 5
2. Pressure spring.
3. Calibration adjuster screw.
4. Seal.
5. Plug.
25790
40
the threaded plug on the pressure relief valve and
extract the la washer.
20434
41
22. Remove the pressure relief valve adjuster screw.
27859
42
23. Turn the control valve body over and complete
disassembly by extracting the spring and the
pressure relief valve piston.
20436
43
Pressure relief valve components (order of disas-
sembly--assembly).
1. Pressure relief valve. 1 2 3 4 5
2. Pressure spring.
4. Seal.
5. Plug.
27099
44
24. Thoroughly clean all control valve component
parts.
25. Replace the washers and seals.
26. Carefully check all mechanical parts, replacing

components that show signs of wear.
27. Before re--fitting, lubricate the components with

hydraulic oil.
28. Re--fit the rotating valve on the sleeve, checking

that the reference marks indicated in the drawing 24712
coincide. 45
29. Use tool 293389 to insert the flat and curved
springs (12, fig. 3).
Spring assembly diagram (12, fig. 3 neutral position

for OSPC 80 ON--150N 1058 hydrostatic steering).
24728
46
30. After inserting the springs in the seat, align and
centre (as shown in the drawing).
24729
47
31. Fit the neutral position spring retaining ring on
the valve seat sleeve, remembering that the ring
must rotate freely without being impeded by the
springs.
24730
48
32. Insert the sleeve--rotor drive shaft trim pin.
24731
49
33. Fit the thrust bearing, following the order and indi-
cations shown in the drawing below.
24732
50
1. Bearing external ring.
2. Thrust bearing.
1
3. Bearing internal ring with bevel facing contact surface
of part (5). 2
4. Rotating valve.
5. Rotating valve seat sleeve. 3
4
5
24733
51
34. Position the control valve body so that the hous-
ing seat on the rotating valve sleeve is positioned
horizontally.
35. Lubricate the VARISEL seal (3) with grease and

fit on the outer edge of the guide bushing (1) of
tool 293955.
27824
52
36. Position tool 293955 complete with components
(1) and (2) and the VARISEL seal (3) on the hy-
drostatic steering control valve body (4).
37. Press fully down, whilst simultaneously rotating
the outer bushing (1) on the tool, in order to facili-
tate the entry of the VARISEL seal (3) in the con-
trol valve body seat.
38. Using the bushing (1), press on the shaft (2), in
the direction indicated by the arrow, in order to
overcome the pressure exerted by the inner
spring. Extract the tool from the control valve
body when the tapered part of the shaft (2) is re-
leased from the seal (3). 27825
53
39. Insert the parts that were previously fitted in op-
erations 26 to 31, on the control valve body, hold-
ing the sleeve-- rotor drive shaft trim pin in a hori-
zontal position, to prevent it from slipping out and
jamming in the slots inside the control valve body.
24739
54
40. Press the rotating valve so as to bring the thrust
bearing into contact with the control valve body.
27826
55
41. Rotate the control valve body and insert the non--
return valve ball into the seat indicated by the ar-
row.
24741
56
42. Screw the threaded plug into the non--return
valve seat until the upper surface is below the
coupling surface of the control valve body.
24742
57
43. Insert the non--return valve balls into the two
seats indicated by the arrows.
27861
58
44. Insert the springs on the backflow valve pins.
27862
59
45. Position the pins, complete with springs, in the
backflow valve seats.
27863
60
46. Lubricate the O--ring seal and insert in the seat on
the control valve body.
24746
61
47. Fit the thrust washer, so that the holes coincide
with the holes on the control valve body.
24748
62
48. Make a reference mark on the upper part of the
teeth (1), near the seat (2), to indicate the exact 1
position of the valve--sleeve trim pin.
24748
63
49. Fit the rotor drive shaft into the control valve body,
insert tool 293390 for retaining and centring the
rotor drive shaft, between the rotor drive shaft
and the thrust washer, rotating the shaft so as to
facilitate coupling between the seat (2, fig. 63)
and the trim pin installed on the sleeve.
24749
64
50. To re--fit the rotor, proceed as follows:
a) each time the hydrostatic steering is disas-
sembled, turn the rotor over so as to limit wear to the
splined coupling;
b) in the following drawing, the rotor shaft has been
removed in order to show the timing between the ro-
tor, rotor drive shaft and the trim pin;
c) fit the rotor on the drive shaft, remembering that
correct timing is obtained by aligning the teeth (1), on 1
the trim pin axis plane (shown in drawing 64 with the
centre line of one compartment on the rotor.
24750
65
51. Lubricate the two O--ring seals (1) with hydraulic
oil and insert them in the rotor fixed ring seat, fix
in position by aligning the retaining holes (2) with
those present on the thrust washer.
24751
66
52. Fit the cover aligning the retaining holes with
those present on the rotor fixed ring.
24753
67
53. Remove retaining tool 293390 and fit the special
screw and washer in the non--return valve seat,
shown in the drawing.
24754
68
54. Fit the other six cover retaining bolts with the
washers and tighten in diagonal sequence to the
torque setting value shown in the table on page
2.
24755
69
55. Turn over the control valve body and insert (see
component details in fig. 44) the pressure relief
valve piston in the seat indicated in the drawing.
24756
70
56. Insert the pressure relief valve spring.
24757
71
57. Using an 8 mm Allen wrench, insert the pressure
relief valve calibration screw.
NOTE: calibration will be carried out on the work-

bench or on the tractor to the values shown in the
table on page 2.
24758
72
58. Tighten plug (2) with the relative seal, using an 8
mm (0.3150 in.) Allen wrench, tightening to the
prescribed torque value of 40 to 60 Nm (30 to 44 1
lfb.lb), after having carried out the calibration op-
eration on the workbench or on the machine.
59. Insert the two balls (1) into the cylinder safety 2
valve seats, indicated by the arrows (see compo-
nent details in fig. 77).
25789
73
60. Insert the springs (2, fig. 77) in the safety valve
seats.
27865
74
61. Using a 6 mm (0.2362 in.) Allen wrench, tighten
the two cylinder safety valve calibration adjuster
bolts (3, fig. 77).
NOTE: calibration will be carried out on the work-

bench or on the tractor to the values shown in the
table on page 2.
20475
75
62. Tighten the two plugs (5, fig. 77) and the relative
seals (4) using a 6 mm (0.2362 in.) Allen wrench.
Once calibration is completed, tighten to the pre-
scribed torque value of 30 Nm (22 lfb.lb).
20429
76
Cylinder safety valves components (order of disas-
sembly--assembly) 1 2 3 4 5
1. Cylinder safety valve ball.
2. Pressure spring.
4. Seal.
5. Plug.
25790
77
63. When the unit has been assembled, insert the
dust seal in the seat on the control valve body.
24764
78
Op. 41 204 38
HYDROSTATIC STEERING CONTROL 1
VALVE
Bench testing
A -- CHECKING ROTATING VALVE WEAR
7
1. Make the connections shown fig. 81 and com-
plete the circuit as in fig. 79.
Using the splined drive shaft (1, fig. 80) hold the 6 2
hydrostatic steering control valve in the steering
position (right or left).
2. Using the handwheel (5), increase the circuit
pressure to approach the pressure relief valve
setting (page 2), without allowing the valve to in-
tervene.
3. Apply a torque wrench (2) to the drive shaft (1)
and tighten to a setting of approx. 34 Nm (25
lfb.lb), check that the rotating valve takes more 5
than ten seconds to complete one full rotation. If
less than ten seconds, replace the complete con-
trol valve. 3
Test conditions.
Oil type . . . . . . . . . . . . . . . . . . . IDRAULICAR AP51
Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W 24911 4
Oil temperature . . . . . . . . . . . . . . . . . 60_C (140_F) 79
Hydraulic pump capacity . . . . . . . . . . . dm3/min 12
1. Splined drive shaft -- 2. Plug G 1/2” -- 3. To the restriction -- 4. Ex-
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (gal./min) 3.17
haust -- 5. Three--way coupling G 1/2” -- 6. From delivery line -- 7. Dis-
Electric motor speed . . . . . . . . . . . . . . . . . 1450 rpm charge coupling G 1/2”.
1 2
24912
80
Installation diagram of equipment for testing the rotating valve, seals and for pressure relief valve calibration.
1. Splined drive shaft. 4. Restriction.
2. Torque wrench. 5. Pressure adjustment handwheel.
3. Delivery.
B -- CHECKING RETURN TO NEUTRAL POSITION E -- CYLINDER SAFETY VALVE CALIBRATION
In the same test conditions as A, check that the rotat- For steering to the left
ing valve automatically returns to the neutral position 1. Make the connections as shown in the diagram in
when the drive shaft (1, fig. 80), is released after each fig. 80, and complete the circuit as in fig. 81.
simulated steering movement. 2. Using the drive shaft (1, fig. 80), simulate a turn
C -- SEAL CHECK to the left (counter--clockwise rotation) so as to in-
In the same test conditions as A, hold the rotating terrupt the oil flow to the discharge.
valve in the steering position with the drive shaft (1)
3. Gradually increase the in the circuit by turning the
for approx. three minutes and check the seals for
handwheel (5), and check on the pressure gauge
leaks.
that the pressure relief valve (26, fig. 3), is acti-
D -- PRESSURE RELIEF VALVE CALIBRATION vated at the pressure shown on page 2.
1. Make the connections as shown in the diagram in If the pressure differs from the prescribed value, in-
fig. ( 80) and complete the circuit, as in fig.( 79). crease or reduce the valve setting (26, fig. 3), by tight-
2. Using the drive shaft (1, fig. 80) simulate a turn (to ening or slackening the adjuster screw.
the left or to the right) so as to interrupt the oil flow
to the discharge. For steering to the right
3. Gradually increase the in the circuit by turning the Make the connections as shown in the diagram in
handwheel (5), and check on the pressure gauge fig. 80 and complete the circuit, as in fig. 82. Proceed
that the pressure relief valve (24, fig. 3) is acti- in the same manner as described above, by simply re-
vated at the pressure shown on page 2, If not, in- versing the direction of rotation of the drive shaft (1).
crease or reduce the pressure relief valve setting
by tightening or slackening the adjuster screw.
25800
3
3
25799 82
Cylinder safety valve calibration for steering
81 to the right
Cylinder safety valve calibration for steering 1. From delivery line -- 2. To the restriction --
to the left 3. Discharge.
1. From delivery line -- 2. To the restriction --
3. Discharge.
CHECKING THE HYDROSTATIC STEERING
PRESSURE RELIEF VALVE WITH CONTROL
VALVE INSTALLED ON TRACTOR.
Proceed as follows:
1. Start the engine and perform a few steering

movements with the tractor, until the oil reaches
a temperature of approx. 122o C.
2. Switch off the engine and detach the oil delivery

pipe union (1) on the hydraulic cylinder (2).
3. Replace the original union with unions (4 and 3),

and connect the pressure gauge (5) with a scale 27151
of 0 to 147 bar (0 to 2132.2 psi) with kit 292870. 83

1. Hydraulic cylinder oil delivery pipes.
2. Hydraulic cylinder.
3. Union 291318 ( supplied with kit 292870 ) to be con-
4. Start the engine again, bring the speed to me- nected to the pressure gauge (5).
dium rpm and apply full steering lock to bring the 4. Union 293874 ( supplied with kit 292870) to be fitted
hydraulic cylinder to the stroke end position. in the place of the original union.
5. Pressure gauge, supplied with kit 292870.
In this condition, the pressure relief valve (24, fig. 3)

should intervene, with the pressure gauge showing
the value prescribed on page 2.
5. If the pressure gauge reading deviates signifi-

cantly from the prescribed value, adjust the valve
(24, fig. 3) by means of the adjuster screw.
SECTION 41 -- STEERING
Chapter 2 -- Non--Stop Flow Gear Pump
CONTENTS

41 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings -- Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chapter 1 Section 35
41 206 20 Power steering oil pump Disassembly -- Assembly (with unit removed) . . . . . . . . . . . . . . . 3
MAIN SPECIFICATIONS OF HYDRAULIC PUMP A 25

rear transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on right--hand side of motor
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 25
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by engine shaft
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . counter--clockwise
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.08
Maximum speed of rotation (with engine at maximum power
2300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 2484
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min 28.19
(gal./min) (7.45)
Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min 11.35
(gal./min) (3)
Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . . . . . . . . mm 17.400 to 17.418
(in.) (0.6850 to 0.6857)
Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 to 17.470
(in.) (0.6870 to 0.6878)
Clearance between gear shafts and seats on supports . . . . . . . . . . . . mm 0.032 to 0.070
(in.) (0.0013 to 0.0028)
-- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
(in.) (0.0039)
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.020 to 0.064
(in.) (0.0008 to 0.0025)
Maximum wear on pump body, suction side, at position of gears . . . . mm 0.1
(in.) (0.0039)
Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 18.323 to 18.348
(in.) (0.7214 to 0.7224)
Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 19.796 to 19.812
(in.) (0.7794 to 0.78)
Width of pump body for gear seats and supports . . . . . . . . . . . . . . . . . mm 58.072 to 58.122
(in.) (2.2863 to 2.2883)
Axial clearance of gears complete with supports in pump body
(recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.100 to 0.200
(in.) (0.0039 to 0.0079)
MAIN SPECIFICATIONS OF HYDRAULIC PUMP A 31 XRP2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with incorporated
regulated output, oil suction
from rear transmission casing.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 31 XRP 2
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEW HOLLAND
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by engine shaft
counter--clockwise
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.08
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum speed of rotation (with engine at maximum power 2300 rpm) rpm 2484
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min 34.77
(gaI./min) (9.19)
Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min 14
(gaI./min) (3.7)
Start of flow control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 1216
Flow control valve output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min 18 to 22
(gaI./min) (4.76 to 5.81)
Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . . . . . . . . . mm 17.400 to 17.418
(in.) (0.6850 to 0.6857)
Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 to 17.470
(in.) (0.6870 to 0.6878)
Clearance between gear shafts and seats on supports . . . . . . . . . . . . . mm 0.032 to 0.070
(in.) (0.0013 to 0.0028)
-- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
(in.) (0.0039)
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.020 to 0.064
(in.) (0.0008 to 0.0025)
Maximum wear on pump body, suction side, at position of gears . . . . . mm 0.1
(in.) (0.0039)
Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.000 to 24.015
(in.) (0.9449 to 0.9455)
Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.490 to 24.510
(in.) (0.9642 to 0.9650)
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . mm 73.135 to 73.160
(in.) (2.8793 to 2.8803)
Maximum wear on pump body, suction side, at position of gears) . . . . mm 0.100 to 0.180
(in.) (0.0039 to 0.0071)
Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full--flow, with replaceable pa-
per cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on pump intake
Tightening torque
PART Thread
Nm lfb.lb
Pump control coupling hub locknut . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 20 UNF 29 22

25719
A 25 pump components
1. Nut. 8. Driven and driving gear shafts.

2. Safety washer. 9. Gear support.
3. Circlip.
10. Pump body.
4. Driving shaft seal.
11. Front cover.
6. Cover seals. 12. Safety washer.
7. Gear support. 13. Bolt.
25720
A 31 XRP 2 pump components
1. Plug. 14. Seals (13).

2. Seal ring. 15. Spacer.
3. Cursor seat (12). 16. Cover seals.
4. Spring. 17. Pump body.
5. Washer. 18. Gear support.
6. Bolt.
19. Driven and driving gear shafts.
7. Plug.
20. Gear support.
8. Seal ring.
9. Safety ring.
10. Seal ring. 22. Driving shaft seal.
11. Fifth wheel 23. Circlip.
12. Cursor. 24. Safety washer.
13. Control valve body. 25. Nut.

The hydraulic pump is of the gear type with spur gears The rear hydraulic pump controls the hydrostatic
and function with non--stop flow according to the en- steering and various services: front and rear differen-
gine rpm. tial lock, power take--off and relative brake, four wheel
It is fitted on the rear side of the right hand engine sup- drive engagement, POWER SHUTTLE gear.
port and are driven by a shaft gear unit. Supplied with a control valve to reduce the quantity of
The oil is taken from the rear transmission casing, pass- oil sent at high speeds.
ing through a filter.
A 31 XRP 2 PUMP MODEL
OP. 41 206 20
HYDROSTATIC STEERING OIL PUMP
(with the pump removed)
DISASSEMBLY
WARNING
Handle all parts carefully. Do not put your hands or 2
Proceed as follows:
1. Remove the bolts (6, fig. 2) and the relative safety
washers (5).
2. Remove the nut (25) that secures the sleeve to the 25227
pump driving shaft and the safety washer (24).
3. Remove the control side cover (21), the circlip
(23) and the seal (22). 3
Assembly
4. Mark the parts (17, 18, 19 and 20), in order to re--
fit them in the same position, if in good condition. WARNING
5. Remove the supports (18 and 20), and gears (19) Always use appropriate tools to align fixing holes.
from the control side cover (21) and the pump body NEVER USE YOUR FINGERS OR HANDS.
(17).
6. Recover the seals (16 and 14) and the anti--extru- 13. To re--fit the pump carry out operations 1 to 7 in
sion rings. reverse order, referring to fig. 2 proceeding as fol-
7. Remove the plugs (1 e 7) with the relative seals, lows:
remove the flow control components from the
to re--fit the pump carry out operations 1 to 7 in re-
body (13), i.e.: the cursor seat (3), the cursor (12),
verse order;
the spring (4).
always ensure maximum cleanliness to prevent
Once the parts are removed, proceed as follows: foreign matter from entering and damaging the
8. Check that the gear contact surfaces are flat and pump;
perpendicular to their supports. Interpose a thin fit together the previously marked parts (17, 18, 19
layer of carbon black. Small rough spots can be and 20), referring to operation 4, in the original posi-
removed using extremely fine and adequately lu- tions;
bricated abrasive paper.
mount the gear supports (18 and 20) in the pump
9. Check that the axial play of the gear--support unit
body, positioning as shown in fig. 2;
in the pump body is 0.100 to 0.180 mm (0.0039
to 0.0071 in.). The distance (2, fig. 3) must be mount the seals (22), on the control side cover
0.100 to 0.180 mm (0.0039 to 0.0071 in.) less (21), facing towards the inside and insert the cir-
than the distance (1). clip (23).
If necessary, true the flat surfaces involved using lu- insert the plastic anti--extrusion rings on the seals
bricated abrasive paper to remove extremely small (14 and 16), fitting between parts (13) (15) (17)
quantities of material. (21), as shown in fig. 2;
10. Clean all constituent parts thoroughly.
Fit the washers (5) and tighten the retaining bolts
11. Replace seals (16 and 22, fig. 2). (6);
12. Lubricate the parts with the same oil used in the
system. Fit the washer (24) and the locknut (25).
SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1 1
SECTION 44 -- AXLES AND WHEELS
Chapter 1 -- Axles and Wheels
CONTENTS
44 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
44 101 22 Front axle hub, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
44 101 30 Front axle, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
44 101 46 Stub axle, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
44 511 80 Checking the alignment of the leading wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MAIN DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . upside down U, telescopic

oscillating at centre
Wheel angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2°, corresponding to
approx.15 mm (0.5906 in.)
for 16” rims
Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0 to 5
(in.) (0 to 0.1968 in.)
Stub axle articulation
Diameter of stub axle pin (7, fig. 2) at bushings (6) . . . . . . . . . . . . mm 37.961 to 38.000
(in.) (1.4945 to 1.4961)
Internal diameter of fitted bushings (6) . . . . . . . . . . . . . . . . . . . . . . ” 38.050 to 38.140 (*)

(1.4980 to 1.5016)
Clearance between stub axle pin and relative bushings . . . . . . . . ” 0.050 to 0.179
(0.0020 to 0.0070)
Axle articulation
Diameter of axle articulation pin (1, fig. 2) . . . . . . . . . . . . . . . . . . . . mm 37.961 to 38.000
(in.) (1.4945 to 1.4961)
Internal diameter of fitted bushings (2) . . . . . . . . . . . . . . . . . . . . . . ” 38.050 to 38.140 (*)

(1.4980 to 1.5016)
Clearance between stub axle pin and relative bushings . . . . . . . . ” 0.050 to 0.179
(0.0020 to 0.0070)
(*) Value to be obtained without refacing.
2 SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1
MAIN DATA
(continued)
Track mm (inches)
Models Tires
A B C D E F G
6.0016
6.5--16 1349 1449 1549 1649 1749 1849 1949

(53.11) (57.05) (60.98) (64.92) (68.86) (72.80) (76.73)
6.50--16 F2
7.50--16
1357 1457 1557 1657 1757 1857 1957
(53.43) (57.36) (61.30) (65.24) (69.17) (73.11) (77.05)
7.50--16 F2
TN55
TN65 9.15L 15 F2
()
TN70 (*)
TN75
27X9.5--15 HF
11L--15 I1
1431 1531 1631 1731 1831 1931 2031
(56.34) (60.28) (64.21) (68.15) (72.09) (76.02) (79.96)
11L--15 F3
25/10LLX15
25/10LLX15 TT
(*) Not available on all markets.
Diagram of 2WD front track
27460
mm
1
SECTIONAL DIAGRAMS
1 2 3 4 5 6 7
18 8
9
17
10
14 13 12 11
16 15
25990
4
2
Sectional views of the stub axle, articulation pin and front axle
1. Axle articulation pin. 10. Bronze thrust ring.

2. Axle articulation bushings. 11. Seal.
3. Steering transverse tie--rod. 12. Wheel hub.
4. Stub axle pin control lever. 13. Tapered roller bearing for wheel.
14. Cover for bearing greasing and adjustment.
5. Axle support.
15. Steel thrust ring.
6. Bushings.
16. Grub screw for cap (11) and thrust
7. Stub axle pin. washer (12).
8. Support ring grub screw (13). 17. Control cylinder fulcrum pin (18).
9. Cap. 18. Control cylinder installation position.
TORQUE SETTINGS
C1 -- 49 Nm
C2 -- 115 Nm
C6 -- 186 to 206 Nm
C5 -- 186 to 206 Nm C5 -- 49 to 68.7 Nm C3 -- (*)
C4 -- 186 to 257.7 Nm
25991
3
Torque settings -- front axle wheel hub side
C1 Retaining bolt for axle articulation pin. C6 Stub axle pin control lever retaining bolt nut.
C2 Retaining bolt holding the disk to the wheel hub. C7 Nut securing cylinder to fulcrum pin.
C3 Bearings adjuster nut.
C4 Axle end securing nut.
C5 Cover for bearing greasing. (*) See operations 12 and 13, page 13
C8 -- 102 to 123.5 Nm
C9 -- 125 to 154.5 Nm
C10 -- 29.4 to 46.4 Nm

25992
Torque settings front axle steering tie--rod side
C8 Stub head locknut for steering transverse tie--rod. C10 Power steering cylinder pipes securing nut.
C9 Locknut for steering transverse tie--rod.
TORQUE SETTINGS
Tightening torque
PART Thread
Nm lfb.lb
Front axle
Axle articulation pin retaining bolt (C1, fig. 3) . . . . . . . . . . . . . . . . . . M 10 x 1.25 49 36
Nut (C2) securing leading wheel to hub . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1.5 115 85
Nut (C3) for bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 20 x 1.5 (*) (*)
Nut (C4) for pin securing end of axle . . . . . . . . . . . . . . . . . . . . . . . . . M 20 x 1.5 186 to 257.7 137 to 190
Cover (C5) for wheel hub bearing greasing . . . . . . . . . . . . . . . . . . . . -- 49 to 68.7 36 to 51
Nut (C6) for stub axles left and right--hand levers retaining bolt . . . M 14 x 1.5 186 to 206 137 to 152
Nut (C7) securing cylinder to fulcrum pin . . . . . . . . . . . . . . . . . . . . . . M 18 x 1.5 186 to 206 137 to 152
Stub head locknut (C8, fig. 4) for steering transverse tie--rod . . . . M 16 x 1.5 102 to 123.5 75 to 91
Locknut (C9) for steering transverse tie--rod . . . . . . . . . . . . . . . . . . . M 20 x 1 125 to 154.5 92 to 114
Nut (C10) securing power steering cylinder pipes . . . . . . . . . . . . . . . -- 29.4 to 46.4 22 to 34
(*) See operations 12 and 13, page 13
TOOLS
List of specific tools required for the various opera-

Warning -- The operations described in this section tions described in this section.
cated by an (X). 292400 Wheel lifting hook.
27855
5
Tool to be made for extracting the front axle articulation pin
(to be used with an extracting tool -- Stamp No. 50145 on the tool -- Measurement in mm)
Construct in C40 material -- Pin 3 x 20 mm (0.1181 x 0.7874 mm).
TROUBLESHOOTING
Abnormal tire wear. 1. Incorrect tire pressure. Inflate the tires to the correct pressu-
re, referring to the recommended
pressures in the Use and Maintenan-
ce handbook, and the pressures indi-
cated by the tire manufacturers.
2. Incorrect front wheel toe--in. Correct the toe--in.
Poor tractor stability. 1. Incorrect tire pressure. Inflate the tires to the correct pressu-
re, following the instructions given
above.
Op. 44 101 22
FRONT AXLE HUB
WARNING
The wheel hubs can be removed without removing

the axle from the tractor.
Proceed as follows for each wheel.
1. Lock the rear wheels using suitable chocks. 25993
2. Lift the front part of the tractor. 6
3. Place a mechanical stand (1) under the engine

sump and insert a wooden block between the en-
gine sump and the stand.
25994
7
4. Remove the front wheel retaining bolts (1).
24767
8
5. Remove the cover (1) for wheel hub bearing
greasing.
1
24775
9
6. Remove the wheel hub bearing adjuster nut se-
curing ring (1).
24776
10
7. Using a socket wrench, unscrew the wheel hub
bearing adjuster nut.
24777
11
8. Remove the wheel hub (2) and recover the bear-
ings (1 and 3).
1 2 3
24778
12
9. Replace worn bearings and faulty seals using

suitable extractors and punches.
24780
13
10. Fill the wheel hub with AMBRA G9 grease.
11. Refit the wheel hub (2), complete with bearings (1
and 3). 1 2 3
24778
14
12. Using a torque wrench, tighten the nut to a torque
of 98 Nm (72 lfb.lb), whilst rotating the wheel hub
(1) to settle the bearings.
1
13. Loosen the nut, then tighten again to a torque of
24 to 29 Nm (18 to 22 lfb.lb) whilst continuing to
rotate the wheel hub.
NOTE: The nut must be replaced each time the wheel

hub is fitted.
24779
14. Check the rolling torque R, bearing in mind that: 15

R ≤ 0.8 kgm (6 lfb.lb)
15. Secure the nut (1) in position.
16. Refit the cover (1, fig. 9) for wheel hub bearing
greasing.
24776
16
0p. 44 101 30
FRONT AXLE Removal--Installation
DANGER
equipment. Make sure that assemblies or parts are
supported by means of suitable slings and hooks.
load to be lifted.
To totally remove the front axle from the tractor, pro-

ceed as follows.

25994
18
24767
19
5. Disconnect the power steering cylinder (2) hoses

(1).
25995
20
6. Remove the axle articulation pin retaining bolt (1).
25996
21
7. Secure the axle by means of a sling (1).
25997
22
8. Extract the axle articulation pin using an extractor
tool (1) fitted with adapter 50145 (see fig. 5) and
extension.
25998
23
9. Remove the complete axle (1).
24772
24
10. To refit the complete axle on the tractor, follow the
disassembly procedure in reverse order. Proceed
as follows.
WARNING
11. Using a bronze punch fit the axle articulation pin

(1). 25996
12. Fit the axle articulation pin retaining bolt (1). 25
13. Connect the hoses (1) of the power steering cylin-

der (2).
14. Fit the front wheels.
15. Remove the support stand.
16. Lower the tractor and remove the sling.

25995
17. Connect the battery negative cable. 26

Op. 44 101 46
STUB AXLE Overhaul
WARNING
Proceed as follows for each wheel, remembering that

the stub axles can be removed without removing the
axle from the tractor.

25994
28
24767
29
5. Position a hydraulic jack under the stub axle and
unscrew the bolt (1) securing the control lever (2)
to the stub axle pin.
24782
30
6. Extract the control lever (1) from the stub axle pin
(2).
24783
31
7. Lower the hydraulic jack and remove the stub
axle (1)
1
24784
32
8. Unscrew the bolts securing the axle end (1).
33
9. Remove the axle end (1).
24786
34
10. Clamp the end of the axle in a vice and, using an
extractor tool, extract the stub axle pin articula-
tion bushings (1).
24787
35
11. To refit the stub axle, follow the disassembly pro-
cedure in reverse order, using a striker to fit the
new bushings on the axle ends.
24788
36
12. Fit the axle end (1).
24786
37
13. Refit the cap (9, fig. 2), at the base of the stub
axle, then the shim adjuster rings (1) inserting
them on the grub screws (8 and 14, as shown in
fig. 2).
24789
38
14. Fit the stub axle on the axle end.
15. Position the control lever (1) on the stub axle pin
(2) then tighten the retaining bolt.
24783
39
Op. 44 511 80
CHECKING THE ALIGNMENT OF THE
LEADING WHEELS
WARNING
fingers between parts. Wear suitable safety clothing A
WARNING
Always use appropriate tools to align fixing holes. A+X
B+0 to 5 mm
Check the alignment of the leading wheels, bearing
in mind that for driving in a straight line, the wheels (0 to 0.1968
must be at an angle of 2° to the ground, correspond- inches)
ing to a difference of approximately 15 mm (0.5906
in.), for 16” rims, between the to and bottom edges of
the rim (fig. a).
B
When driving in a straight line, the wheels must also
be parallel to longitudinal axis of the tractor, or have
a maximum of 5 mm (0.1968 in.) toe--in at the front, 8821
as measured between the edges of the rims.
To check the toe--in exactly, proceed as follows:
1. Inflate the front tires to a pressure of 2.5 bar
(36.26 psi).
2. Position the steering wheel at the middle of its 40
travel, with one spoke along the longitudinal axis
of the tractor.
3. Check that the wheels are parallel with the longi-
tudinal axis of the tractor.
4. On the horizontal plane passing between the
centres of the wheels, measure the distance (B)
between the front inside edges of the rims (see
fig. b).
5. On the horizontal plane passing between the
centres of the wheels, measure the distance be-
tween the rear inside edges of the rims, checking
that the distance is equal to (B) or exceeds it by up
to a maximum of 5 mm (0.1968 in.).
6. If necessary, correct the toe--in by adjusting the
end of the transverse steering tie--rod.
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
SECTION 55 -- ELECTRICAL SYSTEM
Chapter 1 --Instruments
CONTENTS
55 000 Analog instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmitters, sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
ANALOG INSTRUMENTS
5 6 7 8 9 10
13 11
28300
12
1
Instrument panel
Condition Indicator
1. Tractor left--hand turn indicators Flashing (green)
2. Power take--off ON Fixed (yellow)
3. Full beam headlights ON Fixed (blue)
4. Transmission status Fixed (yellow)
5. Power Shuttle alarm Fixed (red)
6. Dry air filter clogged Fixed (yellow)
7. Engine oil pressure low Fixed (red)
8. Low battery charge Fixed (red)
9. Handbrake ON Fixed (red)
10. Tractor right--hand turn indicators Flashing (green)
11. Fuel gauge
12. Speedometer/tachometer
13. Engine coolant temperature
Fuel gauge (Fig. 2).
Shows the fuel level in the tank.
When the tank is full, the pointer moves completely
to the right.
When the tank is less than 1/4 full, the pointer moves
into the red zone.
26312
2
Engine coolant temperature indicator (Fig. 3).
-- Green zone = normal temperature.
-- White zone = temperature too low.
-- Red zone = engine overheating.
In this case, reduce the engine revs to the minimum
(without stopping) and, if the problem persists, check
the cooling system.
26311
3
Speedometer/tachometer (NASO model) (Fig. 4).
Engine rev counter and six--figure hour meter: the fig-
ures on the black background count the hours of work 1
and that on the red background (last figure on the
right) show the tenths of an hour.
The green sector shows the engine speeds for opti-
mum power take--off, at 540 rpm, (1).
-- Green pointer = engine revs with PTO at 540 rpm.
28302
4
HAZARD LIGHTS SWITCH (Fig. 5)

The hazard lights are activated by pressing the red
part of switch (1); the switch will flash together with
the direction indicators.
5
FRONT CORNERING LIGHT SWITCH (Fig. 6)
Press the switch (1) on the yellow port to turn on the
side lights.
6
INDICATOR LIGHTS SWITCH (FIG. 7)
Move the switch (1) to the left to indicate a left--hand
turn.
Move the switch (1) to the right to indicate a right--
hand turn.
7
LIGHTS SWITCH (Fig. 8)
This switch operates with the starter key (1, fig. 9) in
position A.
1. full beam.
2. dipped headlights.
3. side/tail lights.
4. off.
8
STARTER KEY--SWITCH (Fig. 9)
To obtain the three starter key--switch (1) functions,

turn the key to the following positions:
A. All circuits OFF (the key can be extracted). En-

gine stop: automatic operation of fuel injection
shut--off device.
B. Engine start stand--by. Turn signals and instru-

ments operational. Various devices powered up.
C. Engine start: when released, the key returns au-

tomatically to position (B). 9
THERMOSTART PUSHBUTTON (Fig. 10)
To be used when starting the engine in particularly
cold climates.
10
POWER SHUTTLE CONTROL LEVER (Fig. 11)
The lever has three positions:
-- forward (forward gear);
-- back (reverse gear);
-- central (neutral). 11
TRANSMITTERS, SENSORS AND SWITCHES
C B
MDB0703A
12
MDB0704A
13
G H
J I
MDB0705A
14
K
M
O
N
MDB0706A
15
A. BRAKE LIGHTS SWITCHES.

Activates when the brakes are applied.
B. ENGINE OIL PRESSURE SWITCH.

Activates when the engine oil pressure drops below 0.68 bar (10 psi). The warning lamp lights up.
C. ALTERNATOR.
Provides a square wave signal and recharges the battery. The alternator also provides power for the electri-
cal devices on the tractor.
D. AIR FILTER CLOGGED SENSOR.

Activates when the vacuum in the air intake system exceeds a pre--stabilised value. The warning lamp lights
up.
E. PARKING BRAKE SWITCH.

The switch closes when the parking brake is applied.
F. GEARS IN NEUTRAL SWITCH.

Indicates when the gears are in neutral.
G. ENGINE COOLANT TEMPERATURE SENSOR.

The temperature transmitter resistance varies in proportion to the coolant temperature, generating a modu-
lated voltage signal that is measured by the instrument.
H. REAR PTO SENSOR.

Activates when the PTO is engaged and enables the PTO to be engaged when it is OFF.
I. FUEL LEVEL TRANSMITTER.

The transmitter potentiometer provides a signal which determines the level in the fuel tank. The level is
shown on the gauge.
J. 4 WD SWITCH.
Activates when there is no oil pressure in the 4 WD control lines. The warning lamp lights up.
K. BRAKE OIL LEVEL SWITCH.

Activates when the brake fluid drops below the minimum level. The warning lamp lights up.
L. C1 GEAR SWITCH.
Indicates the gear engaged (located in front of the G1 switch).
M. G1 GEAR SWITCH.
Indicates the range position.
N. SPEED SENSOR.
Indicates the theoretical tractor ground speed.
O. TRANSMISSION OIL TEMPERATURE SENSOR.

Indicates the oil temperature in the transmission unit.
Chapter 2 -- Starting System
CONTENTS
55 000 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
System testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 201 50 Starter motor, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
55 201 54 Starter motor, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TECHNICAL INFORMATION
SPECIFICATIONS TYPE OF STARTER MOTOR
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MARELLI MT68
Power (kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Maximum current absorbed without load (A) . . . . . . 60 at 11.7 V and 7000 rpm
Direction of rotation (pinion side view) . . . . . . . . . . . . clockwise
45
Minimum switch diameter, mm (in.) . . . . . . . . . . . . . .
(1.7717)
0.1 to 0.4
Maximum armature shaft end--float, mm (in.) . . . . . .
(0.0039 to 0.0157)
TORQUE SETTINGS
PART Nm (lfb.lb)
Starter motor and engine block assembly bolts . . . . 34 (25)

Box on starter motor / ground wire side . . . . . . . . . . . 16 (12)
Solenoid valve wire nuts . . . . . . . . . . . . . . . . . . . . . . . . 7 (5)

Box nuts on starter motor side . . . . . . . . . . . . . . . . . . 10 (7)
Solenoid valve retaining bolts . . . . . . . . . . . . . . . . . . . 5 (3.6)

DESCRIPTION AND OPERATION er closes a series of contacts in order to directly pow-
er--up all four field coils, thereby supplying full power
to the starter motor.
The type of starting system installed depends on the
type of gearbox fitted on the tractor. All systems con- At this stage, one end of the intake coil is connected
sist of an ignition key--switch, heavy--duty wiring, a to the positive battery pole through the starter switch,
starter motor with an electromagnet, a starter relay whilst the other end is connected to the positive bat-
and gear, range gear and PTO control lever switches. tery pole through the solenoid valve contacts. In this
These are the basic circuit components used on mod- manner the intake coil is by--passed, without absorb-
els with a mechanical gearbox. More sophisticated ing power, and the hold coil exclusively maintains the
systems incorporate other components, which en- electromagnet plunger in position.
sure that the engine can only be started in the correct
conditions. The starter motor includes a series of contacts and a
two--part electromagnet plunger that totally closes
A 2.5 kW starter motor is series installed. This motor the contacts, even if the pinion teeth are not perfectly
has four poles, four brushes with integrated electro- in line with the rim gear. When this happens, a clutch
magnet and positive mesh engagement control. spring compresses the pinion, forcing it to engage
completely as soon as the starter motor begins to turn
The electromagnet consists of two parallel--con- over.
nected coils. The low resistance intake coil is
grounded via the engine, whilst the high resistance When the key--switch is released, power to the elec-
hold coil is grounded via the electromagnet body. tromagnet and motor is cut off. The electromagnet re-
turn spring, acting on the adjustable joint mechanism,
When the key--switch contact is closed (with the gear frees the driving pinion from the gear and re--opens
and range gear in neutral and the PTO disengaged) the solenoid valve contacts.
the coils are energised and the plunger is magnetical-
ly drawn into the electromagnet. This movement, A roller--type clutch mechanism is incorporated in the
transmitted by an adjustable joint mechanism, makes driving pinion unit. This prevents the pinion from over-
the driving pinion engage the flywheel rim gear. When speeding if it remains engaged in the flywheel rim
the pinion makes contact with the rim gear, the plung- gear after the engine has started.
TROUBLESHOOTING
The engine does not turn over when the starter key is turned, with gears and range gears in neutral and PTO
disengaged.
Is the battery fully charged ? Re--charge or replace

NO the battery. Is the
YES engine rotating correctly
?
NO
Check the starting circuit wiring. Are all

connections tightened, is the battery correctly
grounded, are there any broken or frayed wires YES Repair the
present, which could cause a short circuit ? wiring
accordingly.
NO
Is the engine Find the cause

seized ? YES of engine
NO
failure.
Turn the starter key: is a value of +12V The coils or

measured on the starter solenoid valve input brushes are
wire (red and black striped wire) ? YES Is the solenoid YES probably faulty, or
valve mechanically
NO triggered? damaged.
NO
The solenoid valve is probably faulty,

remove the motor and check.
Check the starter relay: does the relay
work when the starter key is turned ? NO Replace the
relay
YES
Remove the connector from the relay: is a

value of +12V measured at pin 5 (red and black
striped wire) when the starter key is turned ? YES
Replace the
NO relay
Check the inverter lever, gear and range gear

switches and PTO lever wires: are the wires NO Reconnect the wire
connected ? to the switch
YES
Check the operation and condition of

all switches. NO Replace the
YES switch.
Does the instrument panel display light up when the

starter key is turned ? NO Check that the battery
YES main power supplies
the key--switch (pin 30).
Check the starter key--switch: if the wire is connected and
in good condition, replace the switch.
SYSTEM TESTING
Starting system test on tractor
To troubleshoot the starting system simply and rapid-
ly with conclusive results, use a battery/starter tester
(high discharge rate tester) with incorporated 0 to
20 V voltmeter and 0 to 500 A ammeter.
When using testing devices, follow the test proce-
dures recommended by the manufacturer. If testing
devices are not available, carry out the following pro-
cedure using a standard 0 to 20 V voltmeter and a 0
to 500 A ammeter to check correct starter motor op-
eration, without removing it from the engine.
Before the test:
• check that the battery is fully charged;
• check the condition of all the starting system wir-
ing (no damaged or frayed wires, no loose con-
nections);
• check that the engine is not seized.
Current absorbed on the starter motor circuit

(Fig. 1) 5 1
1. Disconnect the battery (3) ground cable (nega-

tive).
4
2. Disconnect the positive battery cable from the
starter electromagnet (5). Connect the positive
lead of an ammeter (1) to the positive battery ter-
minal and the negative lead to the electromagnet
input terminal (5).
3 2
3. Reconnect the ground wire (negative) to the bat-
26630
tery negative terminal (3).
1
4. Connect the positive lead on the voltmeter (2) to
the battery positive terminal and the negative
lead to the battery negative terminal.
5. Disconnect the injection pump closing solenoid
valve wire.
6. Run the engine and note voltmeter and ammeter
readings. Voltage must remain constantly around
12 V with an absorption value of 250 to 300 A.
• If the absorption value corresponds with the tech-
nical data, the starter motor (4) is working correct-
ly. If voltage drops during the test, carry out the
”Starting system circuit resistance” test (see the
relative heading).
• If the absorption value exceeds that of the techni-
cal data, check the circuit as described below. If
the starting system circuit tests are satisfactory,
then the starter motor is faulty and will need to be
removed in order to identify the cause.
• If the current absorption value is lower than that
of the technical data, then the starter motor is
faulty and will need to be removed in order to
identify the cause.
Starting system circuit resistance (voltage drop)
(Fig. 2)
If the voltage absorption value is too high, check the
individual circuit components to find the cause of the
voltage drop.
IMPORTANT: Disconnect the injection pump shut--
off solenoid valve wire.
Positive battery cable

2 1
V
the positive terminal on the battery (2).
3
2. Connect the negative lead on the voltmeter to the
starter motor electromagnet terminal (3).
3. Run the engine and check the voltmeter read-

ings. If voltage exceeds 0.2 V, check and tighten
26631
the cable connections. Re--check the voltage
and, if the value is still too high, replace the cable. 2
Starter motor ground connections (Fig. 3)
2 1

the starter motor casing (2).

engine block (3).

ings. If the value exceeds 0.2 V, check the ground 3
26632
connections between the starter motor flange
and the engine rear cover. 3
Battery ground lead (Fig. 4)

2 1
V
the engine block (2).

negative terminal on the battery (3).

ings. If voltage exceeds 0.2 V, check and tighten
the ground cable connections. Re--check the volt- 3
26633
age and, if the value is still too high, replace the
ground cable. 4
Op. 55 201 50
STARTER MOTOR
Removal -- Installation (Fig. 5)
1. Disconnect the negative battery cable.
2. Remove the plastic guard (3) on the terminals.
3. Unscrew the nut and remove the power and

emergency switch terminal (4).
4. Extract the three retaining bolts (2) on the starter

26633
motor (1).
5
5. To reassemble the starter motor, carry out the re-
moval operations in reverse.
26635
6
Starter motor components
1. Electromagnet 7. Field coils and casing

2. Electromagnet nuts 8. Brush holder
3. Bolt and stud assembly
9. Brush plate
4. Control side support
5. Lever 10. Armature
6. Reduction unit 11. Clutch
OVERHAUL 2. Disconnect the biggest braided cable that con-

nects the field coils casing with the electromag-
OP. 55 201 54 net.
STARTER MOTOR, DISCONNECTED 3. Remove the three screws from the front casing
Disassembly -- Assembly and extract the electromagnet. Remember that
the plunger remains connected to the control le-
Refer to figure 6. ver.
1. Position the starter motor in a vice with padded 4. Remove the electromagnet plunger by raising
jaws. and releasing it from the control lever.
5. Remove the two nuts from the rear casing and the 9. Remove the circlip that holds the control unit and
two screws that secure the rear cover and the the inner plate to the armature shaft, by first re-
brush plate to the casing. Remove the ”C” clamp moving the circlip retaining collar perpendicularly
and the armature shaft end--float adjustment using a suitably sized piece of piping. Then lever
shims, leaving the brush gear on the switch. the circlip from the groove.
Remove the fine metal washer from the switch
side of the armature. 10. Extract the armature and control unit.
6. At this stage of the procedure, check the brushes REASSEMBLY

and the switch. Check that the brushes are not 1. To reassemble the starter motor, carry out the re-
stuck together and, if necessary, clean both the moval operations in reverse.
brushes and the respective channels with a cloth
Before reassembly, check the armature axial end--
soaked in kerosene. Also check that the brushes
float and test the starter motor (without load).
are not worn. If the minimum length is less than
that shown in the technical data, the starter motor
will need to be replaced. ARMATURE AXIAL END--FLOAT
1. Position the starter motor in a vice with padded

jaws and connect a dial gauge to the flange on the
NOTE: The brushes cannot be serviced separately. control side of the casing. Position the dial gauge
They are welded to their support and do not require pointer on the end of the armature shaft.
replacement during the entire operating life of the
starter motor. 2. Push the armature fully forward and zero--set the
dial gauge. Push the armature fully back and note
the reading on the instrument.
7. Extract the motor casing from the armature and 3. Readings must fall within the limits specified in
the bracket on the control side. the technical information table. If the value is
higher, check the armature and brush plate are
8. Extract the control lever knuckle pin from the con- not worn. Replace worn parts and, if necessary,
trol side of the casing. check the end--float again.
Starter motor test (without load) (Fig. 7)
6 7
NOTE: a fully charged battery and a battery/starting
tester (high discharge rate tester) with a carbon bat- 1
tery (variable load resistance) are required to carry
out this test.
5
2
1. Position the starter motor in a vice with padded
jaws.
2. Connect the negative cable on the battery (4) to
the starter motor assembly flange. 3
4
3. Using a short cable, make a bridge (7) between
26636
the electromagnet contacts (6).
4. Connect the positive lead on a voltmeter (3) to the 7
positive terminal on the battery (4) and the nega-
tive lead to the negative terminal on the battery.
Connect the positive lead on the ammeter(1) to
the positive terminal on the battery (4) and the
negative lead to the battery or the starter motor
terminal.
5. Position a manual tachometer (5) on the end of
the armature shaft. The maximum power absorp-
tion, which is a specific value for each starter mo-
tor, must be within the range of values shown on
the TECHNICAL INFORMATION table. Adjust
the carbon battery voltage (2) and the armature
rpm to the values shown on the table.
6. If the starter motor does not work according to the
technical information specifications, check to see
if the field coils are grounded, the armature
scrapes or if the armature shaft is deformed.
BENCH TESTS
1
ARMATURE (Fig. 8)
1. The switch surface must be clean and not burnt.
If necessary, remove the burn stains with fine
sandpaper -- not abrasive fabric. Finally, clean the
switch with a cloth soaked in kerosene.
2. If the switch needs re--facing, make sure that the
diameter is not below the minimum value pre-
scribed in the TECHNICAL INFORMATION
table. After re--facing, the switch must be pol-
ished with fine sandpaper and cleaned with a
cloth soaked in kerosene. 26637
8
NOTE: do not cut the armature metal when making
insulation slots.
3. Armature insulation can be checked by connect-
ing an ohmmeter (1) between switch segments
and the armature shaft. This reading should show
infinity, i.e.: there should be no continuity.
4. To test for short circuits in the armature, use a
suitable test instrument or, as the only alternative,
try replacing the armature.
5. If the armature circumference has obviously
made contact with the pole pieces, the pole bear-
ings are probably too worn. First check that the
pole pieces are fixed and that the armature ro-
tates correctly in a lathe. If necessary, replace the
armature bearings.
Field coils (Fig. 9)

1. To test the field coils insulation, connect an ohm-
meter to each of the coil brushes in turn and to a
clean and unpainted area of the casing. No read-
ings should be taken, i.e.: there should be no con-
tinuity.
2. To test the field coils continuity, connect an ohm-
meter to each of the coil brushes in turn and to the
main power terminal (the biggest braided cable).
The reading should be 1 Ω.
3. If there is a fault in the field coils, replace the en-
tire box and field coils system. 1
26638
Bearing bushings 9
1. Check if the bushing on the brush plate and the
box on the drive pinion side are worn. Assemble
the armature shaft and observe the end--float.
Replace the bushings if end--float is excessive.
Check the field poles to see if there are any signs
of scraping against the casing. This could also be
caused by worn bushings.
Drive pinion
1. Check roller clutch operation. The pinion must
only rotate clockwise. If the pinion is either locked
or spins in both directions, or if the pinion teeth
are damaged, assemble a new control unit.
If there is clear evidence of damage to pinion teeth,
check flywheel rim gear, as described in Section 10.
Chapter 3 -- Charging System
CONTENTS

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
System testing and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 301 10 Alternator, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
55 301 12 Alternator, Removed, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TYPE OF ALTERNATOR
SPECIFICATIONS MAGNETI MARELLI
AA125R--14V--45A AA125R--14V--65A
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounded negative
Direction of rotation (pulley side) . . . . . . . . . . . . . . . . . Clockwise
Rated voltage (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maximum rotation speed (rpm) . . . . . . . . . . . . . . . . . . 10.000
Maximum output (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 65
Regulator controlled voltage (V) . . . . . . . . . . . . . . . . . 13.6 to÷14
Inductor coil resistance(Ω) at 25°C (77°F) . . . . . . . . 3.0 to 3.2 2.6 to 2.8
Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RTT119AC
TORQUE SETTINGS
PART Nm (lfb.lb)
Alternator fastening bolts . . . . . . . . . . . . . . . . . . . . . . . 5.5 (4)

Pulley retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 (51)
Rectifier fastening screws . . . . . . . . . . . . . . . . . . . . . . 4.0 (3)

Brush box and regulator screws . . . . . . . . . . . . . . . . . 2.7 (2)
Terminal nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 (2)

Description of the alternator

A Magneti Marelli--type 45 or 65 A external cooling
fan alternator is fitted on all models. The stator wind-
ing is ventilated with an air conducting diaphragm in
the support on the rectifier bridge side and peripheral
openings in the support on the control side. The alter-
nator, installed on the left--hand side of the engine, is
operated by a pulley and a V--type driving belt. The
alternators are fitted with a built--in regulator.
28002
45 or 65 A alternator.
1
1. Battery connector (B+ terminal)
2. Terminal protection sheath
3. Alternator charge indicator connection (D+ terminal)
4. Socket W
5
2
2
26640 Alternator charging circuit
1. Starter switch 5. Alternator

2. Alternator charge warning light B+ : Battery connection
3. Battery D+ :Alternator charge indicator
4. Alternator electronic voltage regulation circuit
Alternator operation The direct current is then reintroduced into the circuit
to increase the current flow through the rotor field
See figure 2. winding.
When the starter key is turned, low current passes This action causes a constant increase in the rotor
from the battery through the rotor field wiring. The cir- magnetic field, together with a rapid increase of cur-
cuit closes, powering the charge warning light, the al- rent and voltage output.
ternator D+ terminal, the rotor field winding, the alter-
As the generated voltage output (reflected by the D+
nator regulator and ground.
terminal) increases, the warning light intensity de-
At this point the warning light illuminates and the rotor creases and, when the voltage at the D+ terminal
is partially magnetised. equals that on the battery side of the warning light, the
light switches off.
When the engine starts and the rotor, which is partial-
Voltage continues to increase until it reaches the pre-
ly magnetised, rotates inside the stator windings,
stabilised regulated voltage level.
three--phase alternating current is generated. A
constant quantity of this current is transformed into di- If the driving belt breaks, there will be no voltage ac-
rect current by three field diodes incorporated in the cumulation in the alternator. The charge warning light
rectifier unit. will remain on -- indicating the presence of a fault.
27374 27375
3 4
Ventilator belt tensioner
Fig. 3. Belt for models without air conditioning Fig. 4. Belt for models with air conditioning
1. Belts 1. Belt tensioner
2. Belt tensioner nut 2. Belt tensioner nut
A. Belt tension A. Belt tension
SYSTEM TESTING AND TROUBLESHOOTING

Precautions 1. Battery check
To avoid damaging alternator charging system com-
Check all battery elements with a densimeter. The
ponents, take the following precautions:
battery must be at least 70% charged and efficient.
• DO NOT MAKE OR BREAK any charging circuit

2. Driving belt check
connection, including the battery, when the en-
gine is running. Inspect the alternator driving belt and pulley, making
sure that they are both clean and in good condition,
• NEVER SHORT CIRCUIT the alternator positive with no traces of oil or grease.
terminal to check if it is working.
Periodically check the alternator driving belt tension.
• ALWAYS DISCONNECT battery cables when If the belt tension is insufficient, check the belt ten-
re--charging the battery on the tractor with a bat- sioner as indicated below.
tery charger. Belt for models without air conditioning (Fig. 3).
• ALWAYS CHECK battery polarity when installing -- Loosen the nut (2) that fastens the alternator
a battery or using a supplementary battery to start to the tensioner bracket;
the engine. -- With a lever, move the alternator (1) on the
tensioner bracket until the correct tension (A)
• DO NOT SHORT CIRCUIT regulator input/out-
of 10 to 11 mm (0.3937 to 0.4331 in.) on the
put terminals whilst the alternator is working.
belt (1) is reached, then tighten the retaining
• CONNECT POSITIVE TO POSITIVE AND nut (2) to a torque value of 78 to 98 Nm (58
NEGATIVE TO NEGATIVE. to 72 lfb.lb).
Belt for models with air conditioning (Fig. 4).
Preliminary checks -- Loosen the belt tensioner (1) retaining nut (2);
Before carrying out electrical tests, carefully inspect -- move the belt tensioner arm (1) on the brack-
the charging system and the electrical system in gen- et until the correct tension (A) of 12 to 13 mm
eral. (0.4724 to 0.5118 in.) on the belt is reached,
Check continuity in all conductors and connections, then tighten the retaining nut (3) to a torque
making sure they are correctly tightened. value of 78 to 98 Nm (58 to 72 lfb.lb).
Correct deflection values, measured by applying the If the warning light does not switch off, stop the engine
following loads to the middle of the belt, are as fol- and disconnect the D+ terminal wire. If the warning
lows: light switches off, one of the alternator components
is faulty. Carry out the ”ALTERNATOR COMPO-
NENTS TEST ”, as described in this section.
Model If the warning light remains on, check that there are
Model
without cab, no grounded short circuits between the D+ wire end-
with cab,
or cab ings and the warning light.
with air
without air
conditioner
conditioner
Preliminary tests
Load N 78 to 98 78 to 98
Deflection mm 10 to 11 12 to 13 The preliminary tests can be carried out without re-
(inches) (0.3937 to (0.4724 to moving any components from the tractor charging cir-
0.4331) 0.5118) cuit. The tests check:
• the alternator wiring connections
• the alternator charging current and controlled
voltage
NOTE: If the belt is cracked or requires frequent ser-
vicing, replace with a new belt. • voltage drops in the alternator charging circuit
• maximum alternator output
The following testing devices are required:
3. Warning light check
• 0 to 30 V mobile coil voltmeter
Turn the starter key and check that the warning light
is fully illuminated. • 0 to 1 V millivoltmeter
If the warning light does not illuminate completely, • 0 to 110 A mobile coil ammeter
check the light bulb. If the light bulb is in working or- • 1.5 Ohm 110 A variable load resistance.
der, carry out the alternator wire connection tests, as
described under the heading ”PRELIMINARY
TESTS” in this section. NOTE: Most commercially available testing devices
If the warning light is on, start the engine and run at include several devices in the same case. Use these
a speed above the idling speed. The warning light devices according to the manufacturer’s instructions.
should switch off.
1. Alternator wire connection tests
See figure 5.
1. Disconnect the battery.
2. Disconnect terminals B+ (2) and D+ (3) on the al-
ternator.
3. Reconnect the battery and turn the starter key to
ON, without starting the engine. Connect a volt-
meter (4) between each terminal and ground (1).
Voltage must be present at the battery.
If there is not voltage at the battery, find and repair the
continuity failure in the external wire circuit. See the
26643
circuit diagram in figure 2.
4. Connect the D+ terminal warning light (red) to 5
ground. The warning light should switch on.
5. Disconnect the battery and reconnect the pre-
viously disconnected connectors to the alterna-
tor.
NOTE: If the warning light does not switch on when

the wire is reconnected to the alternator, there is a
fault either in the alternator regulator or the rotor cir-
cuit. Make sure that the D+ terminal is clean and then
test the alternator components as described in this
section.
2. Charging current and regulated voltage tests

See figure 6.
1. Make sure that all tractor electrical devices are
switched off and that the starter key is in the OFF
position.
2. Disconnect the battery negative terminal and
the B+ alternator terminal (3).
3. Connect an ammeter (1) between the discon-
nected wire (red) (4) and the alternator B+ termi-
nal.
4. Connect a voltmeter (2) between the B+ alterna-
tor terminal and ground. 26644
5. Reconnect the battery. Start the engine and run 6

at 2000 rpm. Note the readings on the voltmeter
and ammeter.
The voltmeter readings should be higher than the bat-
tery voltage and, when the ammeter value falls below
10 A, the voltmeter reading should stabilise at 13.6 to
14 V.
If the voltmeter reading is higher than 14 V, the alter-
nator regulator must be replaced, as described in this
section. (After installing a new regulator, carry out
tests 4 and 5).
If the voltmeter reading is lower than 13.6 V, there is
either a faulty component on the alternator or a failure
due to excessive resistance in external charging sys-
tem connections.
If the ammeter indicates zero A, one of the alternator
components is faulty. Switch off the engine and carry
out alternator components test, as described in this
chapter.
3. Charging circuit voltage drop tests

(a) Insulated side voltage drop tests
See figure 7.
Make sure that the starter key is in the OFF position.
1. Disconnect the negative battery cable and the B+
alternator wire (1).
2. Connect a millivoltmeter (5) between the positive
battery terminal and the D+ wire (3) (positive side
of the wire).
3. Connect an ammeter (2) between the B+ alterna-
tor terminal and the D+ wire (negative side of the
26645
wire).
4. Reconnect the negative battery cable and con- 7
nect a variable load resistance (4) with the cursor
in the minimum current absorption position (maxi-
mum resistance) through the battery terminals.
5. Start the engine and increase speed to 2000 rpm.
6. Gradually increase the resistance charging load
(decreasing the resistance) until the ammeter in-
dicates 45 or 65 A, according to the type of alter-
nator.
7. Note the reading on the millivoltmeter, which
should not exceed 400 millivolt.
Readings higher than 400 millivolt indicates a fault
due to excessive resistance on the external circuits.
If the alternator cannot produce the requested output
and the reading on the millivoltmeter is lower than 400
millivolt, there is a faulty component in the alternator.
Carry out the alternator component tests as de-
scribed in this section.
8. Stop the engine.
(b) Ground side voltage drop test
See figure 8.
1. Make sure that the starter key is in the OFF posi-
tion.
2. The circuit is the same as that described in the
previous test, except that the millivoltmeter (4) is
now connected between the negative battery ter-
minal and the alternator casing (negative side of
the casing).
NOTE: Make sure that the variable load resistance

26646
(3) is in the minimum current absorption position
(maximum resistance). 8
3. Start the engine and increase speed to 2000 rpm.

(decreasing the resistance) until the ammeter in-
dicates 45 or 65 A, according to the type of alter-
nator.
5. Note the reading on the millivoltmeter, which
should not exceed 200 millivolt
Readings higher than 200 millivolt indicates a fault
due to excessive resistance on the external circuits.
If the alternator cannot produce the requested output
and the reading on the millivoltmeter is lower than 200
millivolt, there is a faulty component in the alternator.
Carry out the alternator component tests as de-
scribed in this section.
6. Stop the engine.
4. Maximum alternator output test
See figure 9.
1. Make sure that the starter key is in the OFF posi-
tion.
2. Disconnect the negative battery cable and the al-
ternator B+ wire (4).
3. Connect an ammeter (5) between the B+ alterna-
tor terminal and the D+ wire (1) (negative side of
the wire).
4. Connect a voltmeter (3) between the alternator 26647
B+ terminal (4) and ground.

9
5. Reconnect the battery, start the engine and in-
crease speed to 2000 rpm.
(2) (decreasing the resistance) until the ammeter
indicates 45 or 65 A, according to the type of alter-
nator.
7. Note that the voltmeter reading does not fall be-
low 13.6 V.
readings of less than 13.6 V indicate the presence of
a faulty alternator component. Carry out the alterna-
tor component tests as described in this section.
Alternator component tests
The alternator component tests must only be carried
out if the INITIAL CHECKS have shown the presence
of a faulty alternator component, allowing the follow-
ing checks to be performed:
• the regulator,
• rotor field winding continuity,
• rotor brushes, springs and contact rings.
NOTE: The previously described component tests

can be carried out with the alternator installed on the
tractor. In order to carry out the other alternator com-
ponent tests, remove the alternator from the tractor.
See the section REMOVAL, INSTALLATION AND
OVERHAUL in this chapter.
OP. 55 301 10
ALTERNATOR. Removal -- Installation
IMPORTANT: Before disconnecting the alternator
wires, make sure that the starter key is in the OFF
position -- alternator removal.
1. Lift the bonnet.
2. Carry out operation 90 100 80: Protective mesh,
only removal of right--hand guard (see section
90).
3. Disconnect the two wires B+ (1, fig. 11) and D+
(2, fig. 11) from the alternator.
4. Loosen and remove the nut and bolt (3, fig. 11)
fastening the alternator to the belt tensioner (4, 10
fig. 11).
5. Move the alternator to slacken the belt tension (1,
fig. 13), then remove from the alternator pulley (2,
fig. 13).
26648
11
1 2 3 4 5 6 7 8
10 9
26650
12
Alternator components
1. Pulley retaining nut 6. Stator
2. Pulley 7. Rear support plate
3. Cooling fan 8. Rectifier bridge
4. Front support plate 9. Guard
5. Rotor 10. Electric voltage regulator with incorporated brushes
Alternator pivot (Fig. 13) 1

1. Belt
2. Pulley 3
3. Alternator retaining bolt 28011
13
Secure the alternator horizontally to a suitable sup-
port, with the inner contact surfaces protected by
padding.
Remove the guard (1) after having unscrewed the al-

ternator retaining nuts (Fig. 14).
Before dismantling the alternator completely, carry
out the operations and checks described on the fol-
lowing pages.
26651
14
Rotor and regulator field circuit test
Required testing devices:
• 12 V battery
• multitester
• 2 watt test lamp.
See figure 15.
1. Disconnect all alternator wires.
2. Connect a 12 V battery and a 2.2 watt test lamp
(2) in series between D+ (1) and the alternator
casing (negative side of casing).
3. The test lamp should light up. 26652
If the test lamp does not light up, then the rotor circuit 15
is faulty. Check the brushes, contact rings and field
winding continuity of the rotor.
If the test shows that these components work satis-
factorily, then the regulator may be faulty.
Checking the continuity of three stator windings
Position the points of an ohmmeter (regulated on the Ω

Ω x1 scale) so that they touch the stator phase ends
(a -- b -- c) in the three possible ways shown in figs. 16
-- 17 -- 18. Each three readings should show the
same resistance value.
If resistance is infinite or zero, the measured phase
is either interrupted or short--circuited, therefore the
stator will need to be replaced.
26653
16
26654
17
26655
18
Checking the diodes
Disconnect the terminal wire connector (1) of the ex-
citation diodes from the positive brush pin (Fig. 19).
26656
19
Unweld stator winding terminals (2) from the rectifier
bridge (Fig. 20).
26657
20
Excitation diodes test
Insert an ohmmeter point in the connector (1) men-
tioned above (Fig. 19).
The second point must be placed in contact with each
of the three terminals (A-B-C). Repeat the three mea-
surements after inverting the instrument points
(Fig. 21).
26658
21
Positive power diode tests
Place an ohmmeter point in contact with the positive

(X) alternator terminal and the other successively
with each of the three terminals (A-B-C) (Fig. 22).
Repeat the three measurements after inverting the
instrument point connections.
26659
22
Negative power diode tests
Place an ohmmeter point in contact with negative (Y)

diode plate and the other successively with each of
the three terminals (A-B-C) -- (Fig. 23).
Repeat the three measurements after inverting the
instrument point connections.
26660
23
In the three tests described above, the instrument
should show resistance at each terminal (A-B-C). In-
verting the instrument points, there should be no re-
sistance (Fig. 23). If there is resistance in both cases,
then the diodes are short--circuited. Otherwise, with
an R=0 value (interrupted diode), replace the entire
rectifier bridge.
ROTOR
Check on rotor winding resistance measured

between pins connected to brushes
Disconnect the excitation diode terminal wire connec-

tor (1) from the pin connected to the positive brush.
Place both points of an ohmmeter (regulated on a Ω
x1 scale) in contact with the two voltage regulator--
brush holder pins.
If the resistance reading is different from the pre- 26661
scribed value, or if it is infinite (interrupted circuit),
check and replace the rotor if necessary (Fig. 24). 24
OP. 55 301 12
ALTERNATOR, REMOVED
Fit a suitable Allen wrench in the hexagonal hole on

the alternator shaft to prevent it from moving. With
another wrench unscrew the fan and rotor pulley. Ex-
tract these parts, together with the spacers and alter-
nator shaft washers (Fig. 25).
26662
25
Disconnect the excitation diode terminal wire connec-
tor (2) from the pin connected to the positive brush.
Unscrew the screws (3) securing the electronic volt-
age regulator (4), complete with brushes, to the rear
alternator support.
Unscrew the nuts (5) and extract the screws that fas-
ten the alternator main external parts (Fig. 26).
26663
26
Electronic voltage regulator (Fig. 27)
A. Brushes
B. Pins
26664
27
Separate the parts (as illustrated) bearing in mind that
a considerable degree of pressure on the rotor shaft
is required to free the front support plate (6) and the
rotor (7) (Fig. 28).
If a press is not available, use a brass striker to avoid

damaging the thread.
26665
28
Remove the screws (9) that secure the rectifier bridge
(10) to the rear support plate (8) (Fig. 29).
The rectifier bridge must not be disassembled: it is
supplied as a whole spare part.
26666
29
Separate the rectifier bridge (10) from the rear sup-
port plate and unweld the stator winding terminals
(11) (Fig. 30).
26667
30
Separate the stator (12) and the terminals (11) from
the rear support plate (8) (Fig. 31).
26668
31
Inductor winding insulation test

x1 scale) in contact respectively with a slip ring and
the rotor casing (see arrows). The instrument should
show infinite resistance. If this is not the case, replace
the rotor (Fig. 32).
26669
32
Check on inductor (rotor) resistance on slip rings
x1 scale) in contact respectively with the rotor slip
rings (see arrows). The instrument should show a
certain degree of resistance (Fig. 33).
If the resistance reading is different from the pre-
scribed value, or if it is infinite (interrupted circuit), re-
place the rotor.
Check that the bearing rotates freely, without sticking
or making noise.
Check that the brushes have not dented the rings. If
this is the case, replace the whole rotor.
26670
33
Assembly
4
To assemble, reverse the order of the disassembly
operations. 2
OVERHAUL
1. Check that the rotor and stator poles are not
worn. If this is the case, either the bearings are
worn, the boxes are not aligned or the rotor shaft
is deformed. 1
NOTE: the alternator bearings cannot be serviced
3
26671
separately, therefore they must both be changed
when necessary. 34
2. Remove the bearing lock (3) plate (2) securing

screws (1) then remove the front support plate (4)
(Fig. 34). Check for wear and damage and, if
necessary, replace.
Before installing the bearing, check the front sup-
port plate holder and clean thoroughly.
3. Installation of bearing (5) on the support plate
side is different from the previous operation. A
new rotor and bearing assembly must be fitted
(Fig. 35).
INSTALLATION
1. Refit the alternator by following the removal 26672
procedure in reverse.
During installation, remember to: 35
• make sure that the negative (ground) battery
cable is disconnected from the battery during al-
ternator installation.
• regulate the alternator driving belt as previously
described in this chapter.
Chapter 4 -- Battery
CONTENTS

55 301 40 Battery removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery problems -- frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TYPE OF BATTERY
SPECIFICATIONS
All models
Voltage (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold start amperage (D.C.A) . . . . . . . . . . . . . . . . 730
Capacity (Ah) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Number of elements . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Weight, kg (lb.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 20 (44)
Grounding terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
DESCRIPTION AND OPERATION Each element of the battery consists of positive and
A ”sealed”, maintenance--free battery is installed in all negative plates, positioned alternatively one next to
models, located behind the driving seat. the other. Each positive plate is separated from the
negative plate by means of a porous insulating sepa-
NOTE: ”Maintenance--free ” means that the battery rator. If one of the positive plates comes into contact
does not leak electrolyte in normal conditions of use. with the negative plates in the element, the element
Leaks may occur if the battery is charged over 14.4 will short circuit and be irreparably damaged. All of
V. This causes the liquid to boil as a result of the gas the positive plates are welded to a bar and form a pos-
formed whilst the battery is fully charging. This event itive terminal, whereas all of the negative plates are
may be caused by a charging system fault, quick re- welded to a similar bar and form a negative terminal.
charging or topping up.
Each positive plate comprises a lead grid with lead
The four main functions of the battery are: peroxide pasted to the grid holes. The negative plates
• to supply a source of electric energy for starting, consist of a lead grid with lead sponge pasted to the
switching on and running the instruments; grid holes.
• controlling the electrical system;
• to supply electricity when the power required is The plates are covered by electrolyte formed by a di-
higher than that produced by the alternator; luted sulphuric acid solution.
• to support inactive loads from the radio and the
microprocessor memory. The battery casing is made in polypropylene.
OP. 55 301 40
BATTERY Removal -- Installation
REMOVAL
88 Ah Battery installed in front of the engine

(Figs. 1 and 2)
28004
1. Raise the engine hood. 1
2. Loosen the bolts on both terminals and discon-

nect the negative (2) and positive (1) cables from
the battery, making sure that they do not touch
the battery (Fig. 1).
3. Loosen the battery securing bolts on the front

side.
4. Using the handles (1), fitted on both ends of the 28003

battery, lift and remove the battery from its hous-
ing (Fig. 2). 2
INSTALLATION
Applicable to all types of battery
1. To re--install the battery follow the removal proce-
dure in reverse, with the following precautions:
• Make sure that the battery is clean and there are
no traces of electrolyte leakage, also check that
the breather covers are correctly installed.
Spread petrolatum (e.g.: vaseline); do not use
traditional lubricants as they favour electrolytic
corrosion.
• Make sure that the battery housing and support
are clean without objects (stones, etc.) which
could pierce the battery casing.
• Make sure that the battery terminal polarity is cor-
rect and that the terminal connections are not too
tight.
• If a radio is installed, all data stored in the memory
will be lost and it will need to be reprogrammed.
Electronic control units and microprocessors --
when installed -- will not lose stored data, as elec-
tronic stress and transmission control calibration
are not involved in this operation.
BATTERY CHECKING AND MAINTENANCE Maximum battery life can be achieved by taking care
of and regularly checking the battery. The energy ca-
RELATIVE DENSITY pacity output must not be exceeded by a constant/ex-
cessive overload and charging requirements must be
The relative density of the battery electrolyte shows
respected.
the charge level of the battery. When the battery is ful-
ly charged, the relative density of the electrolyte is at
least 1.280 at 25°C (77°F).
Alternatively, the approximate charge status can be BATTERY MAINTENANCE
measured by using a digital voltmeter
(± 0.01V), as follows:
Less than 10.5 V Battery is unusable* WARNING
Less than 11.8 V Battery flat Batteries contain sulphuric acid and generate a highly
Less than 12.3 V Battery half--charged explosive hydrogen and oxygen mix during charging.
More than 12.6 V Battery fully charged
* See the notes under the heading ”TESTS” for in- • Never use devices that produce flames or sparks
structions on how to recover a slightly sulphured whilst checking the electrolyte level.
battery. • Always protect hands and eyes before removing
The battery voltage must be measured on a flat bat- the battery caps.
tery, considering the following:
P. the battery must have been flat for at least four During battery maintenance, observe the steps noted
hours; below:
Q. if the vehicle has been used recently, switch the
headlamps on for two minutes. 1. Keep the electrolyte at the recommended level of
When a battery is flat, the sulphuric acid in the elec- 17 mm (0.6693 in.) over the plates. If this level is
trolyte combines chemically with the plates, thereby not respected, the acid concentration will in-
decreasing the relative density of the solution. crease, which could cause damage to the sepa-
rators and diminish plate performance.
A battery densimeter will determine the relative den-
sity of the electrolyte in an element, and the quantity 2. Only use distilled or demineralized water, never
of sulphuric acid not used in the solution indicates the overfill or use tap/rain water or other sources of
degree of charge of that element. water.
Low temperatures require a higher battery charge to
operate. For example, a battery with a relative density 3. Keep the battery 75% charged (at least) to avoid
of 1.225 at 27°C (80°F) can activate the starter motor plate sulphurisation, performance loss and pos-
at ambient temperatures, but will fail to do so if the sible freezing at low temperatures.
temperature drops as a result of poor battery perfor-
4. Avoid overcharging the battery, as excessive
mance levels.
charge will generate high internal heat, causing
Table 1 shows the effects of temperature on battery grid deterioration water leaks.
performance.
Table 1 5. During rapid recharging, make sure that the bat-
tery temperature does not exceed 50°C (122°F).
Fully charged battery
Temperature 6. Do not add sulphuric acid to an element unless
performance
electrolyte has been spilled. Before topping up,
25.0°C (77°F) 100% make sure that the solution has the correct rela-
--4.5°C (--40°F) 82% tive density. Slow recharging is the only way to
--24.0°C (--75°F) 64% fully recharge the battery. Use a high amperage
--27.5°C (--81.5°F) 58% battery charger to charge the battery with high
--31.0°C (--88°F) 50% current intensity for short periods of time, but this
--34.5°C (--94°F) 40% must be followed by a slow charge to achieve full
--37.5°C (--99.5°F) 33% capacity battery performance.
DRY--CHARGED BATTERIES can lead to violent boiling in the battery, thereby

Dry--charged batteries must be prepared as follows: damaging the internal components.
1. Remove the breather caps from the battery ele- 3. Re--check the level of the electrolyte in each ele-
ment. ment and add distilled water as needed.
2. Fill each element to the recommended level with WARNING
electrolyte, at the relative density of 1.260.
Explosive gas is formed when a battery is charged.
Do not smoke or use naked flames when checking
NOTE: The electrolyte is formed with sulphuric acid, the electrolyte level and make sure that the battery
diluted at a temperature of 21° to 32° C (69.8° to charger is switched off before connecting or discon-
89.6° F). necting, to avoid sparks that may ignite the gas.
3. After filling, leave the battery to rest for 15 min-
utes, then check the electrolyte level and top up CHARGING EXTREMELY FLAT BATTERIES
if required.
4. Charge the battery for 4 hours at 5 to 8 A, making To recharge a Pb--Ca maintenance--free battery, we
sure that all of the elements are freely producing recommend a constant voltage battery charger. For
gas. extremely flat batteries, charge for 48 hours at 16 V,
5. Refit the breather caps on the battery element. with current limitation (50A for 100Ah).
This method is self--regulating: high current is pro-
vided at the beginning (when the battery voltage is
very low), whilst current decreases progressively
CHARGING THE BATTERY when the battery è fully charged (and the voltage is
Before charging a battery: high).
1. Thoroughly clean the battery casing, the covers If only constant voltage battery chargers are avail-
on the elements and the terminals with diluted able, we recommend using the voltage levels and
ammonia or warm water. times shown in Table 2. These figures refer to ex-
2. Check the level of the electrolyte in each element tremely flat batteries. If the battery is only 50%
and, if found to be under the plate level, top up charged, use half the time shown (slow charging pro-
with distilled water to cover the plates. grams). For other conditions, reduce charging time
proportionally. When possible, use the slowest charg-
NORMAL CHARGING (TOP UP) ing program to increase battery life.
1. Fully charge the battery using a slow battery char- Table 2
ger at 3 to 6 A for the required time. This operation
could take 36 hours or more if the battery is ex- Type of battery
tremely flat. A severely sulphured battery may not
88 Ah
charge at all. When the battery is fully charged,
(730 dca)
the elements produce gas freely and the relative
density will remain constant. Disconnect the bat- Slow charging 23 hours at 5a
tery charger after three consecutive densimeter programs 11.5 hours at 10A
readings taken each hour, to show that the rela- Rapid charging
tive density has stopped increasing. programs (emergency 6 hours at 10A
2. When using a rapid or fast ampere charge, follow use only)
the manufacturer’s instructions carefully. High
charging amperage increases the electrolyte If violent boiling occurs during recharging, due to gas
temperature and, if the battery charger is not formation or electrolyte leakage (50°C, 122°F, or
fitted with an automatic timer or thermostat, this more), temporarily reduce or stop battery charging to
temperature may exceed 50°C (122°F), which avoid damaging the battery.
TESTS 5. If the relative density is less than 1.280, charge
Before beginning battery tests, check that the breath- the battery and check the charging system to de-
ers are not blocked, there is no rust, the breather caps termine the cause of the low charge.
are not open and the casing is not cracked.
NOTE: If distilled water has been added recently, re-
Equipment required for testing: charge the battery for a short time, otherwise the
• Densimeter densimeter will not provide precise readings.
• Battery starter tester
(high amperage multi--tester) If the battery has been charged under static condi-
tions, a thicker electrolyte will accumulate at the bot-
• Thermometer tom of the elements. The battery must be shaken at
• Battery charger regular intervals in order to mix the electrolyte. This
will improve the charging amperage and provide
Relative density: This test shows the charge level of more precise densimeter readings during the tests.
the battery.
Performance test
1. With the float in the vertical position, note the
reading. The performance test helps us to understand if the
battery can adequately start the engine. Voltage
2. Adjust the densimeter reading for battery electro- readings show the battery condition. Before carrying
lyte temperature variations, subtracting 4 points out the test, check that the electrolyte level is correct
(relative density 0.004) for every 5.5°C (42°F) be- and the open circuit voltage is 12.5V or more. The
low the calibrated temperature of the densimeter battery can either be tested whilst fitted on the tractor
and adding 4 points (relative density 0.004) for or removed.
every 5.5°C (42°F) above this temperature. 1. Switch the battery start tester current control to
The following examples have been calculated with a OFF (high amperage discharge tester). Calibrate
densimeter calibrated at 30°C (86°F). the voltage selection switch to the rated battery
voltage, or slightly higher. Connect the positive
Example 1: tester conductors to the positive terminal on the
Temperature below 30°C (86°F) battery and the negative conductors to the nega-
Electrolyte temperature 19°C (66°F) tive battery terminal.
Densimeter reading 1.270
2. Turn the current control knob until the ammeter
Subtract 11.0 x 0.004
reading reaches half the cold start battery amper-
5,5
age and note the voltage reading.
Correct relative density = 1.262
• If the reading shows 9.6 V or more after 15 sec-
Example 2: onds, the battery has adequate power output and
Temperature above 30°C (86°F) can be easily charged following the normal proce-
Electrolyte temperature 40°C (104°F) dure.
Densimeter reading 1.220 • If the reading is below 9.6 V, the battery is not sat-
Add 10.0 x 0.004 0.007 isfactory for use and must be tested as described
5,5 below.
Correct relative density = 1.227
3. Use the following table to define the charge level. WARNING: Do not leave high discharge on the bat-
tery for more than 15 seconds.
Correct Correct
Charge
relative relative Average Test charge: This test is only for batteries that failed
density density battery to pass the previously described performance test.
level
at 15°C at 25°C voltage 1. Connect the positive battery starter conductors
(59°F) (77°F) (high amperage discharge tester) to the positive
100% 1.295 1.287 12.66 battery terminal and the negative conductors to
75% 1.253 1.246 12.45 the negative battery terminal.
50% 1.217 1.210 12.30 2. Connect the positive battery charger conductor to
25% 1.177 1.170 12.00 the positive terminal on the battery and the nega-
Flat 1.137 1.130 11,84 tive conductor to the negative battery terminal.
3. Turn the battery charger timer to more than the ”3
minute” charge, and then back to the ”3 minute”
NOTE: The relative density should not vary more charge.
than 0.025 points between cells. 4. Set the charging amperage as close as possible
to 40 A.
4. If the relative density is 1.280 or more, the battery 5. After 3 minutes of rapid charging, read the volt-
is fully charged and in good working condition. meter.
• If the total voltage exceeds 15.5 V, the battery is These faults are normally caused by:
not satisfactory and is probably sulphured or 1. Component failure inside the element.
worn and must be replaced.
2. Excessive crystal growth leading to perforated
NOTE: A slightly sulphured battery can be renewed separators and eventual short circuits.
using a multiple--type battery charger, with an upper 3. Excessive overload (inefficient charging system,
open circuit voltage limit of 50 V. A sulphured battery high voltage rapid charging, operation at high
has high resistance and will require high initial voltage temperatures).
to overcome resistance due to sulphurisation. There 4. Battery electrolyte freezing.
may be no visible signs of charging at the beginning. A fully charged battery freezes at --65°C
After a few minutes of inactivity a low charge will be (--149°F). A 50% charged battery freezes be-
shown, followed by a rapid amperage rise. Amperage tween --17°C (--63°F) and --27°C (--81°F). Com-
must not exceed 14.0 A or the temperature of the pletely flat electrolyte freezes at --3°C to --11°C
electrolyte must not exceed 50°C (122°F). When the (--37°F to --52°F). Excessively rapid recharging
amperage has stabilised, reset the voltage until the and boiling caused by gas formation leads to sep-
amperage remains fixed at 5 A. Continue at this level aration of the active material from the grids. Sep-
until the relative density of the electrolyte stops in- aration destroys the chemical function of the bat-
creasing (approx. 1.275 to 1.280 at 20°C (68°F). This tery.
may take 48 hours, then let the battery rest for 24
hours and carry out the previously described perfor- 5. Crystals are formed when batteries are left flat.
mance test. High temperatures and long periods in this condi-
tion accentuate the problem. If a battery is left at
• If the total voltage is below 15.5 V, check the rela- ambient temperature for a week, it will be difficult
tive density of each element and recharge the to recharge on the tractor. Recharging will require
battery according to the following scale: a higher constant voltage. After 3 weeks, the bat-
tery will be permanently damaged and it will be
Relative density Rapid charge up to: necessary to follow the procedure described for
extremely flat batteries.
1.150 or less 60 minutes
from 1.151 to 1.175 45 minutes Fully charged batteries last for longer. A lead--cal-
cium battery discharges 3% every month. This
from 1.176 to 1.200 30 minutes means that in 16 months the charge will drop by 50%.
The inactive load on the tractor is approx. 50mA. An
from 1.200 to 1.225 15 minutes approximate discharge on an unused vehicle is val-
(slow charge only ued at 8Ah per week.
It is worth noting that if a battery is weak during engine
starting, it is best to let the battery rest for a couple of
BATTERY PROBLEMS -- FREQUENT minutes. This rest time should increase as the tem-
CAUSES perature decreases.
1. Internal open circuit. When two batteries are installed, do not use an old
2. Internal short circuit. battery with a new one. One battery will always stop
3. Electrolyte leak. before the other. If the battery has lasted the pre-
scribed amount of time, recharge both the batteries.
4. Grid active material separation.
If a battery stops before the prescribed time, due to
5. Accumulation of sulphate crystals too big to be a manufacturing fault, then only replace one of the
dispersed. batteries.
Chapter 5 -- Electrical Circuits

(Before S/N 1268128)
CONTENTS
55 000 Fuses and relays (Model with cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electric wire colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General diagram -- Central part (electrohydraulic 4WD version. ISO version) . . . . . . . . . . 6
General diagram -- Central part (mechanical 4WD version. ISO version) . . . . . . . . . . . . . . 9
General diagram -- Front part (ISO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General diagram -- Rear part (ISO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lighting circuit diagram (ISO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrohydraulic 4WD and brake lights circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mechanical 4WD and brake lights circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front corner lights and rear work lights circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General diagram -- Central part (Power Shuttle version. NASO version) . . . . . . . . . . . . . 18
General diagram -- Central part (Standard version. NASO version) . . . . . . . . . . . . . . . . . . 21
General diagram -- Front part (NASO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General diagram -- Rear part (NASO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lighting circuit diagram (NASO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FUSES AND RELAYS
1 2 3 4 A
5 6 7 B
12 11 10 9 8 7 6 5
10 15 10 10 15 10 15 15 5 5 15 5
A A A A A A A A A A A A
2
5A 5A 5A 25A
16 15 14 13
FUSE COLOURS B. -- RIGHT--HAND SIDE RELAY
Beige; 5A -- Red; 10A -- Blue; 15A.
A. -- LEFT--HAND SIDE RELAY

5. Starter motor circuit.
1. 4 WD and brake lights circuit.
2. 4 WD and brake lights circuit. 6. PTO Safety circuit.
3. trailer brake ITALIA circuit.
4. trailer brake ITALIA circuit. 7. Flasher circuit.
Main box fuse protection

Valves PROTECTED CIRCUITS Amp.
1 Engine stop electromagnet. 5
2 Thermostarter. 15
3 LH tale/side lights and tale/side lights indicator. 5
4 RH Tale/side lights and controls and instruments lighting. 5
5 Full beam lights. 15
6 Dipped beam lights. 15
7 Trailer brake, PTO safety + instrument common circuit. 10
8 Work lights and corner lights. 15
9 Brake lights and 4 WD circuit. 10
10 Direction indicator. 10
11 Hazard lights and full beam flasher circuit. 15
12 Horn, 8A power socket. 10
13 25A power socket. 25
14 Starter safety circuit. 5
15 Not used. --
16 Not used. --
Main box fuse protection (NASO model)

Valves PROTECTED CIRCUITS Amp.
1 Engine stop electromagnet. 5
2 Thermostarter. 15
3 LH tale/side lights and tale/side lights indicator. 5
4 RH tale/side lights and controls and instruments lighting. 5
5 Full beam lights. 15
6 Dipped beam lights. 15
7 PTO safety circuit, NASO model + instrument common. 5
8 Corner lights and rear light. 15
9 Power Shuttle circuit (+ key). 10
10 Direction indicator. 10
11 Hazard lights, seat safety and flasher full beam circuit. 15
12 8A power socket circuit. 10
13 25A power socket. 25
14 Starter safety circuit. 5
15 Power shuttle circuit (+key). 5
16 Power Shuttle control centre power supply (+battery). 5
SYMBOLS USED IN ELECTRICAL CIRCUITS
Loudspeaker
Starter switch
Diode
Connection
Battery
Solenoid valve
Fuse
Motor Thermostarter
Lighting and
Horn
indicator lamp
Switch relay
Variable resistance
Switch relay Cigar lighter
Pressure switch
Power socket
Control switch
Indicator switch
26091
2
ELECTRIC WIRE COLOUR CODE
A Light blue
B White
C Orange
G Yellow
H Grey
I Blue
M Brown
N Black
R Red
S Pink
V Green
Z Purple
WIRING DIAGRAMS AND CONNECTIONS IDENTIFICATION CODE
0.5 -- RN -- (3)
WIRE SECTION
WIRE COLOUR
CONNECTOR PIN
NUMBER
(where relevant)
GENERAL DIAGRAM -- CENTRAL PART (electrohydraulic 4 WD version. ISO version)
1 Thermostarter. 15 RH light connection.

2 Instrument panel. 16 LH light connection.
3 Starter switch. 17 Brake lights switch.
4 4 WD relay. 18 Brake lights switch.
5 4 WD relay. 19 Thermostarter control button.
6 Trailer brake relay (ITALIA version). 20 Starter relay.
7 Trailer brake relay (ITALIA version). 21 Ground
8 25A connection (engine side). 22 Hazard lights switch.
9 Engine connection. 23 4 WD control switch.
10 Corner lights connection. 24 Corner lights control switch.
11 Front lights connection. 25 Direction indicator control switch.
12 Trailer brake connection. 26 Lights switch.
13 Transmission connection. 27 Electronic flasher.
14 25A connection (transmission side). 28 Fusebox.
GENERAL DIAGRAM -- CENTRAL PART (Mechanical 4 WD version. ISO version)
1 Thermostarter. 15 RH light connection.

2 Instrument panel. 16 LH light connection.
3 Starter switch. 17 Brake lights switch.
6 Trailer brake relay (ITALIA version). 19 Thermostarter control button.
7 Trailer brake relay (ITALIA version). 20 Starter relay.

8 25A connection (engine side). 21 Ground
9 Engine connection. 22 Hazard lights switch.
10 Corner lights connection. 24 Control switch corner lights.

11 Front lights connection. 25 Control switch direction indicator.
12 Trailer brake connection. 26 Lights switch.
13 Transmission connection. 27 Electronic flasher.
14 25A connection (transmission side). 28 Fusebox.
GENERAL DIAGRAM -- FRONT PART (ISO version)
8 25A connection (engine side). 34 Horn.

9 Engine connection. 35 Air filter clogged switch.
10 Corner lights connection. 36 Starter motor.
11 Front lights connection. 37 Engine stop electromagnet.
29 Corner light. 38 Brake fluid level switch.

30 Front LH light. 39 Engine coolant temperature sensor.
31 Front RH light. 40 Engine oil pressure switch.
32 Corner light. 41 Alternator.

33 Battery. 42 Overload safety device.
GENERAL DIAGRAM -- REAR PART (ISO version)
12 Trailer brake connection. 52 Parking brake switch.

13 Transmission connection. 53 Fuel gauge switch.
43 Trailer brake indicator pressure switch. 54 Rear cab light.
44 Electrohydraulic 4 WD indicator pressure switch. 55 8A power socket.
45 4 WD indicator control connection. 56 Seven pole coupling.
46 4 WD solenoid valve. 57 Work light.
47 Mechanical 4 WD indicator switch. 58 Number plate light.
48 Gear switch connection. 59 Rear LH light.
49 Neutral gear switch. 60 Ground.
50 Range gear switch. 61 Trailer brake solenoid valve.
51 PTO indicator switch. 62 Trailer brake safety pressure switch.
LIGHTING CIRCUIT DIAGRAM (ISO version)
2 Instrument panel.
3 Starter switch.
11 Front lights connection.
13 Transmission connection.
22 Hazard lights switch.
25 Control switch direction indicator.
26 Lights switch.
27 Electronic flasher.
28 Fusebox.
30 Front LH light.
31 Front RH light.
33 Battery.
54 Rear cab light.
56 Seven pole coupling.
59 Rear LH light.
ELECTROHYDRAULIC 4 WD AND BRAKE

LIGHTS CIRCUIT DIAGRAM
2 Instrument panel.
4 4 WD relay.
5 4 WD relay.
17 Brake lights switch.

23 4 WD control switch.
28 Fusebox.
44 Electrohydraulic 4 WD indicator pressure

switch.
45 4 WD indicator control connection.
46 4 WD solenoid valve.
54 Rear cab light.
59 Rear LH light.
28
2
17
13
45
59 54 47
MDB1624A
MECHANICAL 4 WD AND BRAKE LIGHTS CIRCUIT DIAGRAM

2 Instrument panel. 45 4 WD indicator control connection.
13 Transmission connection. 47 Mechanical 4 WD indicator switch.
17 Brake lights switch. 54 Rear cab light.
28 Fusebox. 59 Rear LH light.
29 32
10
28
8 8A
24
57
MDB1625A
FRONT CORNER LIGHTS AND REAR WORK LIGHTS CIRCUIT DIAGRAM

10 Corner lights connection. 29 Corner light.
24 Control switch corner lights. 32 Corner light.
28 Fusebox. 57 Work light.

GENERAL DIAGRAM -- CENTRAL PART (Power Shuttle version. NASO version)
1 Thermostarter. 13 Front lights connection.

2 Instrument panel. 14 Corner lights connection.
3 Starter switch. 15 Starter relay.
4 Power Shuttle control centre connections. 16 Ground.
5 Clutch pedal switch. 17 Hazard lights switch.

6 Power Shuttle switch. 18 Control switch corner lights.
7 Clutch pedal sensor. 19 Thermostarter control button.
8 Power Shuttle connections. 20 Control switch direction indicator.

9 Transmission connection. 21 Horn timer device.
10 25A connection (engine side). 22 Lights switch.
11 25A connection (transmission side). 23 Electronic flasher.
12 Engine connection. 24 Fusebox.
GENERAL DIAGRAM -- CENTRAL PART (standard version NASO version)
1 Thermostarter. 16 Ground.
2 Instrument panel. 17 Hazard lights switch.
3 Starter switch. 18 Control switch corner lights.
9 Transmission connection. 19 Thermostarter control button.
10 25A connection (engine side). 20 Control switch direction indicator.
11 25A connection (transmission side). 21 Horn timer device.
12 Engine connection. 22 Lights switch.

13 Front lights connection. 23 Electronic flasher.
14 Corner lights connection. 24 Fusebox.

15 Starter relay.
GENERAL DIAGRAM -- FRONT PART

(NASO version)
11 25A connection.
12 Engine connection.
14 Corner lights connection.
25 Corner light.
26 Front LH light.
27 Front RH light.
28 Corner light.
29 Battery.
30 Air filter clogged switch.
31 Starter motor.
32 Engine stop electromagnet.
33 Brake fluid level switch.
34 Engine coolant temperature sensor.
35 Engine oil pressure switch.
36 Alternator.
37 Overload safety device.
GENERAL DIAGRAM -- REAR PART

(NASO version)
38 PTO indicator switch.
39 Neutral gear switch.
40 Rear RH light.
41 8A power socket.
43 Work light.
44 Rear LH light.
45 Ground.
46 Fuel gauge switch.
47 Parking brake switch.

48 Seat switch.
LIGHTING CIRCUIT DIAGRAM

(NASO version)
2 Instrument panel.
3 Starter switch.
20 Control switch direction indicator.
22 Lights switch.
24 Fusebox.
29 Battery.
40 Rear RH light.
44 Rear LH light.
Chapter 6 -- Electrical Circuits

(After S/N 1268128)
CONTENTS

55 000 Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Location of fuses and relays (mechanical shuttle and power shuttle versions) . . . . . . . . . 4
Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electric wire color code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to use the linear wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical circuits (mechanical shuttle and power shuttle versions) . . . . . . . . . . . . . . . . . . . 11
Ground location points (mechanical shuttle and power shuttle versions) . . . . . . . . . . . . . . 11
Front part circuit (mechanical shuttle and power shuttle versions) . . . . . . . . . . . . . . . . . . . 13
Starting circuit (mechanical shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starting circuit (power shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Operator safety circuit description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
Operator safety circuit (mechanical shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Operator safety circuit (power shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
Front lights circuit (mechanical shuttle and power shuttle versions) . . . . . . . . . . . . . . . . . . . E
Lighting circuit (mechanical shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F
Lighting circuit (power shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
4WD and brake lights circuit (mechanical shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . H
4WD and brake lights circuit (power shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Transmission circuit (mechanical shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J
Transmission circuit (power shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K
Transmission circuit (power shuttle version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L
Power Shuttle electronic control unit inputs/outputs wiring diagram . . . . . . . . . . . . . . . . . . . M

ELECTRICAL CIRCUIT COMPONENTS
1 Thermostarter.
2 Instrument panel.
3 Starter switch.
13 Mechanical 4WD jumper connection (12 PIN)
14 40 A Maxi fuse.
19 Thermostarter switch.
20 Starter relay.
24 Cornering lights switch.
25 Direction indicator lights switch.
26 Lights switch.
28 Fusebox.
29 LH cornering light
30 Front LH head lamp.
31 Front RH head lamp.
32 RH cornering light
33 Battery.
34 Starting engine connector (1 PIN)
35 Air filter clogged switch.
36 Starter motor.
37 Engine stop electromagnet.
38 Brake fluid level switch.
39 Engine coolant temperature sensor.
40 Engine oil pressure switch.
41 Alternator.
42 Overload protection device.
49 Neutral gear switch.
51 PTO indicator switch.
52 Parking brake switch.
53 Fuel gauge switch.
55 8A power socket.
56 7--pole connection.
57 Work light.
63 Dual side LH lamp
64 Dual side RH lamp
65 Seat switch
66 Transmission connection (18 PIN)
67 Brake lights relay
70 G1 range switch
71 C1 gear switch
72 Transmission oil temperature sensor
73 Transmission oil pressure switch
74 HIGH (reverse) clutch solenoid valve
75 LOW (forward) clutch solenoid valve
76 Speed sensor
77 Dump solenoid valve
79 Front head lamp connection (6 PIN)
80 Front connection (10 PIN)
81 Operator safety circuit buzzer timer
82 Buzzer diode protection
83 4WD circuit connection
84 Connection for 7--pole connection (6 PIN)
85 Power Shuttle control unit (ECM)
86 Clutch pedal switch
87 Clutch pedal sensor
88 40 A power socket
89 Power Shuttle control unit troubleshooting connection
90 Power Shuttle control lever
LOCATION OF FUSES AND RELAYS
4WD Mechanical Shuttle and Power Shuttle Version
MPD2808A
RELAYS AND CONTROL UNITS -- RELAYS AND CONTROL UNITS --

LH SIDE (a) RH SIDE (b)
1. Brake lights relay. 1. Starter relay.

2. Alarm module. 2. 40 A Maxi--fuse.
3. Electronic flasher.
Fuses (Mechanical Shuttle Version)
Fuses Amps PROTECTED CIRCUITS
1 5 Engine stop electromagnet.
2 15 Thermostart.
3 15 LH taillights, work lights in 7 PIN trailer socket NASO.
4 5 RH taillights, controls, instrument lighting.
5 15 Full beam headlights.
6 15 Dipped beam headlights.
7 10 PTO safety circuit, + instrument cluster power supply, operator presence (keyed 12V).
8 15 Cornering lights, rear work light.
9 -- Not used.
10 10 Brake lights.
11 25 Hazard and turning lights, full beam flasher circuit.
12 10 8A power socket + 12V operator’s presence system.
13 -- Not used.
14 5 Starter safety circuit.
15 -- Not used.
16 -- Not used.
17 40 NASO power socket Maxi--fuse.
Fuse colors
Color Amps
Brown 5
Red 10
Blue 15
Green 30
Orange 40
Fuses (Power Shuttle Version)
Fuses Amps PROTECTED CIRCUITS
1 5 Engine stop electromagnet.
2 15 Thermostart.
3 15 LH taillights, work lights in 7 PIN trailer socket NASO.
4 5 RH taillights, controls, instrument lighting.
5 15 Full beam headlights.
6 15 Dipped beam headlights.
7 10 PTO safety circuit, + instrument cluster power supply, operator presence (keyed 12V).
8 15 Cornering lights, rear work light.
9 10 Power Shuttle circuit.
10 10 Brake lights.
11 25 Hazard and turning lights, full beam flasher circuit.
12 10 8A power socket + 12V operator’s presence system.
13 -- Not used.
14 5 Starter safety circuit.
15 5 Power shuttle circuit (+ key).
16 5 Power Shuttle control center power supply (+ battery).
17 40 NASO power socket Maxi--fuse.
Fuse colors
Color Amps
Brown 5
Red 10
Blue 15
Green 30
Orange 40
SYMBOLS USED IN ELECTRICAL CIRCUITS
Speaker
Starter switch
Diode
Connection
Battery
Connection
Fuse
Motor Thermostart
Lights
Horn
and warning indicators
Switch relay
Variable resistance
Switch relay Cigar lighter
Pressure switch/Sensor
Power socket
Indicator switch Control switch
MPD2703A
SYMBOLS USED IN ELECTRICAL CIRCUITS (continued)
Switch Solenoid valve
Inductive sensor Solenoid valve
Sensor Flasher
MPD2704A
ELECTRIC WIRE COLOR CODE
A Light Blue HV Grey/green

AN Light blue/black HG Grey/yellow
AG Light blue/yellow I Blue
AB Light blue/white LB Blue/white
AV Light blue/green LN Blue/black
AR Light blue/red LR Blue/red
B White M Brown
BR White/red MB Brown/white
BN White/black MN Brown/black
BL White/blue N Black
BG White/yellow NZ Black/purple
C Orange NB Black/white
CB Orange/white NR Black/red
CN Orange/black R Red
CL Orange/blue RG Red/yellow
G Yellow RN Red/black
GV Yellow/green RV Red/green
GN Yellow/black S Pink
GR Yellow/red SN Pink/black
GL Yellow/blue SG Pink/yellow
H Grey V Green
HM Grey/brown VN Green/black
HR Grey/red VB Green/white
HN Grey/black Z Purple
HB Grey/white ZB Purple/white
HL Blue/Grey ZN Purple/black
WIRING DIAGRAMS AND CONNECTIONS IDENTIFICATION CODE
0.5 -- RN -- (3)
WIRE SECTION
WIRE COLOR
N. PIN
ON CONNECTION
(where relevant)
HOW TO USE THE LINEAR WIRING DIAGRAMS
The wiring diagrams have been drawn in a linear

style. This means that the complete wiring diagram
has been drawn over a number of pages but if joined
together would make a complete diagram.
The wiring is drawn between three lines, two across
the top of the page and one at the bottom of the page.
The upper line (1) marked +30 is the constant live
line.
Below the +30 line is the +15 (2) which is the ignition
key on live line.
The lowest line is the ground/earth line (3).
On the lower part of the page (4) a line is marked with
numbers increasing by ten (10--20--30, etc.). This is 4
the line used to reference wires and components.
2
Example
Figures 3 and 4 show a basic circuit drawn over two
pages.
Power comes in from the ignition on live line +15
through fuse A, which is located at point 230.
Power comes to switch S10. If the switch is operated,
power continues up and stops with an arrow (1) and
a number. The arrow indicates the wire continuing to
another page. The Number 780 refers to the line
reference where it appears on a new page. Note the
line reference directly below the wire being traced,
i.e., 260. Following the line reference until 780 is
found. Using either the index or following the page
reference line. When 780 is located on the reference
line the number 260 will be observed at the top of the
page. Note the arrow points back to the previous part
of the circuit. From this point follow the wire down to
3
solenoid EV6. The diagram now indicates that power
goes to ground.
4
ELECTRICAL CIRCUITS
DESCRIPTION DIAGRAM
Front part circuit (mechanical shuttle and power shuttle versions) A
Starting circuit (mechanical shuttle version) B/1
Starting circuit (power shuttle version) B/2
Operator safety circuit (mechanical shuttle version) C/1
Operator safety circuit (power shuttle version) C/2
Front lights circuit (mechanical shuttle and power shuttle versions) D
Front lighting circuit (mechanical shuttle version) E/1
Front lighting circuit (power shuttle version) E/2
4WD and brake light circuit (mechanical shuttle version) F/1
4WD and brake light circuit (power shuttle version) F/2
Transmission circuit (mechanical shuttle version) G/1
Transmission circuit (power shuttle version) G/2
Transmission circuit (power shuttle version) H
GROUND LOCATION POINTS (Fig. 5 -- page 12)
A. Instrument panel ground.

B. Engine compartment ground.
C. Rear ground.
GROUND LOCATION POINTS
MPD2823A
5
FRONT PART CIRCUIT
(DIAGRAM A)
33 Battery
34 Starting engine connector (1 pin)
35 Air filter clogged switch
36 Starter motor
37 Engine stop electromagnet
38 Brake fluid level switch
39 Engine coolant temperature sensor
40 Engine oil pressure switch
41 Alternator
42 Overload protection device
80 Front connection (10 pin)

FRONT PART CIRCUIT (Mechanical Shuttle and Power Shuttle Versions), DIAGRAM A
50032133
WIRING FOR DIAGRAM A
MPD2810A
6
6L
6L
MPD2711A
7
MPD2712A
8
STARTING CIRCUIT (Mechanical Shuttle Version)
(Diagram B/1)
1 Thermostarter
2 Instrument Panel
4 Low brake fluid level indicator
7 Dry air filter clogged indicator
9 Low battery charge
8 Engine oil pressure low
X Engine coolant temperature
Y Fuel gauge
3 Starter switch
19 Thermostarter switch
20 Starter relay
28 Fusebox
F1 Engine stop electromagnet
F2 Thermostarter
F7 PTO safety circuit, + instrument cluster power supply
F14 Starter safety circuit
66 Transmission connection (18 pin)

STARTING CIRCUIT (Mechanical Shuttle Version), DIAGRAM B/1
50032132
WIRING FOR DIAGRAM B/1
80
68
3
20
86
85
19
90
MPD2811A
9
MPD2713A
10
MPD2714A
11
MPD2715A
12
CN2
CN1
MPD2828A
13
BLANK PAGE ADDED

STARTING CIRCUIT (Power Shuttle Version)
(Diagram B/2)
1 Thermostarter
2 Instrument Panel
4 Low brake fluid level indicator
7 Dry air filter clogged indicator
9 Low battery charge
8 Engine oil pressure low
X Engine coolant temperature
Y Fuel gauge
3 Starter switch
19 Thermostarter switch
20 Starter relay
28 Fusebox
F1 Engine stop electromagnet
F2 Thermostarter
F7 PTO safety circuit, + instrument cluster power supply
F9 Power shuttle circuit (+ running)
F14 Starter safety circuit
85 Power shuttle control unit (ECM)
86 Clutch pedal switch
90 Power shuttle control lever

STARTING CIRCUIT (Power Shuttle Version), DIAGRAM B/2
50032131
WIRING FOR DIAGRAM B/2
80
68
3
20
86
85
19
90
MPD2811A
14
MPD2713A
15
MPD2714A
16
CN2
CN1
MPD2715A
17
MPD2829A
18
OPERATOR SAFETY CIRCUIT (FIG. 19)
DESCRIPTION
The circuit is composed of an alarm module with

acoustic warning device (2) connected to the hand-
brake switch, a sensor located under the driving seat
and the rear PTO switch.
The alarm module is positioned inside the dashboard, MPD2803A

on the LH side, between the brake lights relay (1) and
the light flasher module (3). 19
OPERATION
The circuit operates in three ways:
1. With the engine running and no one seated in the
driving position, with the handbrake disengaged
and the PTO ON/OFF, the alarm is activated.
2. With the engine running and the driving position
occupied, the alarm is always deactivated.
3. With the engine switched off and the driving posi-
tion free/occupied, with the handbrake disen-
gaged and the PTO ON/OFF, the alarm is acti-
vated.
OPERATOR SAFETY CIRCUIT (Mechanical Shuttle Version)
(Diagram C/1)
2 Instrument Panel
2 Power take-off (PTO)
10 Handbrake ON
28 Fusebox
F7 PTO safety circuit + instrument cluster power supply, operator presence (keyed 12V)
F12 8A power socket, + 12V operator’s presence system
PIN 1 -- Power
PIN 2 -- Handbrake switch
PIN 3 -- Operators presence switch
PIN 4 -- Not used
PIN 5 -- Ground
PIN 6 -- Starter switch
PIN 7 -- PTO switch
PTO indicator light
PIN 8 -- Not used
82 Buzzer diode protection

OPERATOR SAFETY CIRCUIT (Mechanical Shuttle Version) -- DIAGRAM C/1
50032130
WIRING FOR DIAGRAM C/1
80
68
3
20
86
85
19
90
MPD2811A
20
MPD2716A
21
MPD2717A
22
MPD2718A
23
OPERATOR SAFETY CIRCUIT (Power Shuttle Version)
(Diagram C/2)
2 Instrument Panel
2 Power take-off (PTO)
10 Handbrake ON
28 Fusebox
F7 PTO safety circuit + instrument cluster power supply, operator presence (keyed 12V)
F12 8A power socket, + 12V operator’s presence system
PIN 1 -- Power (12V)

PIN 2 -- Handbrake switch
PIN 3 -- Operators presence switch
Power shuttle control unit, CN2, PIN 19
PIN 4 -- Not used
PIN 5 -- Ground
PIN 6 -- Keyed 12V
PIN 7 -- PTO indicator light
PTO indicator switch
PIN 8 -- Power shuttle control unit, CN1, PIN 13
82 Diode
85 Power shuttle control unit (ECM)

OPERATOR SAFETY CIRCUIT (Power Shuttle Version) -- DIAGRAM C/2
50032129
MPD2716A
24
1HL (1)
MPD2827A
25
CN2
CN1
MPD2718A
26
THIS PAGE LEFT BLANK

FRONT LIGHTS CIRCUIT
(Mechanical Shuttle and Power Shuttle Versions)
(Diagram D)
29 LH cornering light
30 Front LH head lamp
31 Front RH head lamp
32 RH cornering light
79 Front head lamp connection (6 PIN)

FRONT LIGHTS CIRCUIT (Mechanical Shuttle and Power Shuttle Versions), DIAGRAM D
20032128
WIRING FOR DIAGRAM D
66
MPD2812A
27
MPD2719A
28
LIGHTING CIRCUIT (Mechanical Shuttle Version)
(Diagram E/1)
2 Instrument Panel
1 LH direction indicator light
3 Main beam indicator light
11 RH direction indicator light
W Instrument panel lighting
14 40A Maxi fuse
22 Hazard lights switch
24 Cornering lights switch
25 Direction indicator control switch
26 Lights switch
27 Electronic flasher
28 Fusebox
F3 LH taillights, work lights in 7 pin trailer select NASO
F4 RH taillights, controls, instruments lighting
F5 Full beam headlights
F6 Dipped beam headlights
F7 PTO safety circuit, + instrument cluster power supply, operator’s presence (keyed 12V)
F8 Cornering lights, rear work light
F11 Hazard and turning lights and full beam flasher circuit
79 Front head lamp connecdtion (6 pin)
88 40A power socket

LIGHTING CIRCUIT (Mechanical Shuttle Version), DIAGRAM E/1
50032127
WIRING FOR DIAGRAM E/1
66
MPD2812A
29
MPD2736A
MPD2733A
30
1 BN (A6) (A8) .5 HL
1 LB (A5)
(B7) 1 A
1 RN (A4)
1 L (A3)
1 RG (A2)
(B4) 1 BR)
2.5 C (A1) 27
2.5 C (B1)
1 V (B2)
1 VB (B3)
1 AN (B6)
2.5 N (B8)
31
MPD2735A
32

LIGHTING CIRCUIT (Power Shuttle Version)
(Diagram E/2)
2 Instrument Panel
1 LH direction indicator light
3 Main beam indicator light
11 RH direction indicator light
W Instrument panel lighting
14 40A Maxi fuse
22 Hazard lights switch
24 Cornering lights switch
25 Direction indicator control switch
26 Lights switch
27 Electronic flasher
28 Fusebox
F3 LH taillights, work lights in 7 pin trailer select NASO
F4 RH taillights, controls, instruments lighting
F5 Full beam headlights
F6 Dipped beam headlights
F7 PTO safety circuit, + instrument cluster power supply, operator’s presence (keyed 12V)
F8 Cornering lights, rear work light
F11 Hazard and turning lights and full beam flasher circuit
79 Front head lamp connecdtion (6 pin)
88 40A power socket

LIGHTING CIRCUIT (Power Shuttle Version), DIAGRAM E/2
50032125
WIRING FOR DIAGRAM E/2
66
MPD2812A
33
MPD2736A
34
MPD2733A
35
1 BN (A6) (A8) .5 HL
1 LB (A5)
(B7) 1 A
1 RN (A4)
1 L (A3)
1 RG (A2)
(B4) 1 BR)
2.5 C (A1)
27
2.5 C (B1)
1 V (B2)
1 VB (B3)
1 AN (B6)
2.5 N (B8)
36
1HL (1)
MPD2827A
37
MPD2735A
38
4 WD AND BRAKE LIGHTS CIRCUIT (Mechanical Shuttle Version)
(Diagram F/1)
13 Mechanical 4WD jumper connection (12 pin)
17 Brake lights switch
28 Fusebox
F10 Stop lights
F13 Fuse 13 shown, not used in circuit
83 4WD circuit connection (3 pin)

4 WD AND BRAKE LIGHTS CIRCUIT (Mechanical Shuttle Version), DIAGRAM F/1
50032124
WIRING FOR DIAGRAM F/1
68
66
MPD2815A
39
50032123
MPD2745A
40
1RG (87b)
1BR (87a)
CN (1)
MPD2747A

4 WD AND BRAKE LIGHTS CIRCUIT (Power Shuttle Version)
(Diagram F/2)
13 Mechanical 4WD jumper connection (12 pin)
17 Brake lights switch
28 Fusebox
F10 Stop lights
F13 Fuse 13 shown, not used in circuit
83 4WD circuit connection (3 pin)

4 WD AND BRAKE LIGHTS CIRCUIT (Power Shuttle Version), DIAGRAM F/2
50032122
WIRING FOR DIAGRAM F/2
68
66
MPD2815A
41
50032123
MPD2745A
42
1RG (87b)
1BR (87a)
1HL (1)
CN (1)
MPD2747A

TRANSMISSION CIRCUIT (Mechanical Shuttle Version)
(Diagram G/1)
49 Neutral gear switch
51 PTO indicator switch
52 Parking Brake Switch
53 Fuel gauge switch
55 8A power socket
56 7--pole connection
1 -- Ground
2 -- Work lights
3 -- LH turn light
4 -- Stop lights
5 -- RH turn light
6 -- Tail lamps
7 -- Auxiliary
57 Work light
65 Seat Switch
84 Connection for 7--pole connection (6 pin)
* Turf version.
TRANSMISSION CIRCUIT (Mechanical Shuttle Version) -- DIAGRAM G/1
50032121
WIRING FOR DIAGRAM G/1
MPD2817A
43
1HL (4)
1N (2)
1H (2)
1HG (1)
1B (2)
MPD2751A
44
* Turf version
M (6)
1.5B (1)
V (5)
1.5N (2)
G (3)
R (4)
1A (3)
1RG (2)
1GN (4)
MPD2752A
45
1RG (2)
1GN (4)
1L (4)
1AN (3)
1A (2)
1V (1)
MPD2753A
46
TRANSMISSION CIRCUIT (Power Shuttle Version)
(Diagram G/2)
51 PTO indicator switch
52 Parking Brake Switch
53 Fuel gauge switch
55 8A power socket
56 7--pole connection
1 -- Ground
2 -- Work lights
3 -- LH turn light
4 -- Stop lights
5 -- RH turn light
6 -- Tail lamps
7 -- Auxiliary
57 Work light
65 Seat Switch
70 G1 range switch
71 C1 gear switch
72 Transmission oil temperature sensor
73 Transmission oil pressure switch
74 HIGH (reverse) clutch control solenoid valve
75 LOW (forward) clutch control solenoid valve
76 Speed sensor
77 Dump solenoid valve
84 Connection for 7--pole connection (6 pin)
* Turf version
TRANSMISSION CIRCUIT (Power Shuttle Version), DIAGRAM G/2
50032120
WIRING FOR DIAGRAM G/2
MPD2817A
47
1IH (2)
1N (2)
1HG (1)
1HL (4)
1B (2)
1BV (1)
MPD2754A
48
* Turf version
M (6)
1.5B (1)
V (5)
1.5N (2)
G (3)
R (4)
MPD2755A
49
1HL (1)
MPD2756A
50
1BG (2) 1GL (2)
1AB (1) 1AB (1)
MPD2757A
51
1ZN (1)
1ZB (2)
MPD2758A
52
TRANSMISSION CIRCUIT (Power Shuttle Version)
(Diagram H)
2 Instrument Panel
5 Transmission status indicator
6 Power shuttle alarm
10 Handbrake indicator
28 Fusebox
F7 PTO safety circuit, + instrument cluster power supply circuit, operator presence (keyed 12V)
F9 Power shuttle circuit
F15 Power shuttle circuit (+key)
F16 Power Shuttle control center power supply (+battery)
85 Power Shuttle control unit (ECM)
87 Clutch pedal sensor
89 Power Shuttle control unit troubleshooting connection

TRANSMISSION CIRCUIT (Power Shuttle Version) -- DIAGRAM H
50032119
WIRING FOR DIAGRAM H
80
68
3
20
86
85
19
90
MPD2811A
53
MPD2825A
54
MPD2827A
55
CN2
CN1
MPD2828A
56
MPD2829A
57
POWER SHUTTLE ELECTRONIC CONTROL UNIT INPUT/OUTPUT
WIRING DIAGRAM (8 + 8 and 16 + 16)
1 Starter switch. 1a: starter function -- 1b: gear function.

2 Starter relay.
3 Shuttle control lever. 3a: on engine starter circuit -- 3b: on control unit power supply circuit.
4 Clutch pedal switch for starter circuit.
5 Clutch pedal switch for control unit power supply circuit.
6 Transmission oil pressure gauge indicator.
8 Transmission alarm indicator.
9 Clutch A solenoid valve (forward gear).
10 Clutch B solenoid valve (reverse gear).
13 Dump solenoid valve (hydraulic neutral safety).
14 Handbrake ON output signal for acoustic alarm.
15 Shuttle lever output signal (to 4WD control unit) if in reverse gear selection.
16 Speed sensor amplified signal to instrument panel.
17 Bodywork ground.
18 Sensors ground.
19 Power ground.
20 Connection for troubleshooting unit 294084.
21 Push button Y.
22 Push button B.
23 HMENU selection push button.
24 Troubleshooting unit 294084.
25 Speed sensor.
26 Engine revs counter (from alternator).
27 Handbrake ON switch.
28 Creeper position switch (G1).
29 Transmission oil pressure sensor for control unit activation.
30 Gear shift position switch (C1).
33 To fuse 15.
34 Driving seat safety switch.
35 Transmission oil temperature sensor.
38 Shuttle lever in reverse gear selection position.
39 Shuttle lever in forward gear selection position.
40 Clutch pedal potentiometer signal.
41 Sensors power supply (+5V).
42 Emergency cable for ”limp--home” after electrical breakdown.
43 Battery.
POWER SHUTTLE ELECTRONIC CONTROL UNIT INPUT/OUTPUT WIRING DIAGRAM (8 + 8 and 16 + 16)
2 FUSE 16 (5A)
1a
3a 4 5
3b
FUSE 14 (5A)
6
FUSE 7 (10A)
41
FUSE 9 (10A)
40
FUSE 15 (5A)
8
FUSE 7 (10A)
1b 39
38 9
43
10
NTC 1140 a 0o -- 330 a 40o

35
34
42
33
9
13
30
14
10
29
SW--3
CN2--31
15
28 SW--3 CN2--31
27
16
24
26
680
23
25
22 21 19 18 17
20
MPD2821A
Chapter 7 -- Electrical Components
CONTENTS
55 418 10 Multi--function instrument panel, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
55 440 08 Electronic Control Module (ECM), Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
55 510 20 Fuse box, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 510 22 Fuses--Relays, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Op. 55 418 10
MULTI--FUNCTION INSTRUMENT PANEL
WARNING
Proceed as follows:
1. Remove the instrument panel retaining screws (1). 1
2. Remove the instrument panel (1), disconnecting

the electrical connection and the speedometer/
tachometer.
3. To refit the instrument panel, proceed as follows.
WARNING
-- Refit the speedometer/tachometer, the electrical

connection and reposition the instrument pane.
2
-- secure the instrument panel by means of the re-
taining screws.
OP. 55 440 08
ELECTRONIC CONTROL MODULE (ECM)
Replacement
WARNING
To remove the ECM, proceed as follows:

1. Carry out operation 55 418 10: Multi--function in-
strument panel, only removal (see page 2).
2. Unscrew the retaining screws and remove the
ECM (1) from the support, disconnect the dash-
board electrical connections and remove the
ECM.
3. To refit the ECM, proceed as follows.
WARNING
-- Connect the connections to the ECM and secure

to the support using the screws. 3
-- Carry out operation 55 418 10: Multi--function in-

strument panel, only installation (see page 2).
OP. 55 510 20
FUSE BOX
Replacement
WARNING
Proceed as follows.
1. Remove the cover (1) on the fuse box. 4

2. Remove the retaining screws (1) and remove the
fuse box.
3. To refit the fuse box, proceed as follows.
WARNING
-- Position and secure the fuse box.
-- Refit the cover on the fuse box. 5

OP. 55 510 22
FUSES
Replacement
WARNING
Proceed as follows.
1. Remove the cover (1) on the fuse box.
2. Replace the faulty fuse.
3. Refit the cover on the fuse box. 6
OP. 55 510 22
RELAY Replacement
WARNING
Proceed as follows.
strument panel, only removal (see page 2).
2. Replace the faulty relay.
WARNING

strument panel, only installation (see page 2). 7
SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1 1
SECTION 90 -- PLATFORM, CAB, BODYWORK
Chapter 1 -- Bodywork
CONTENTS
90 100 22 Hood opening, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
90 100 80 Protective grill, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
90 100 84 Hood guard, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
90 110 50 Dashboard, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
90 114 26 ROPS (Roll Over Protection Structure), Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . 9
90 116 10 Right or left--hand mudguard, Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
90 116 24 Rear guard, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1
Op. 90 100 22
HOOD OPENING
WARNING
Proceed as follows:
1. Disconnect the electrical connections (1) of the

front headlamps. 1
2. Remove the two retaining bolts (1) holding the

pivot bracket (1) to the engine.
2
3. Remove the retaining spring and shock absorber
(1) from the upper pivot and remove the hood.
4. To refit the hood, proceed as follows.
WARNING
-- Position the hood and secure the shock absorber

by means of the spring.
-- Fit the pivot bracket on the engine. 3
-- Connect the electrical connections of the front

headlamps.
Op. 90 100 80
PROTECTIVE GRILL
WARNING
Proceed as follows.
27642
1. Remove the three retaining bolts (2), washers
and the LH lateral grill (1). 4
2. Remove the three retaining bolts (1), washers

and the RH lateral grill (2).
3. To refit the grill, proceed as follows.
WARNING
-- Fit the RH lateral grill, washers and the three re- 27643
taining bolts.
5
-- Fit the LH lateral grill, washers and the three re-

taining bolts.
Op. 90 100 84
HOOD GUARD
WARNING
Proceed as follows.
1. Remove the two hood guard retaining bolts and
washers.
2. Remove the hood guard (1) located behind the
exhaust silencer.
3. To refit the hood guard, proceed as follows.
WARNING 27661
Always use appropriate tools to align fixing holes. 6

-- Fit the hood guard located behind the exhaust si-

lencer.
-- Fit the two hood guard retaining washers and
bolts.
Op. 90 110 50
DASHBOARD
DANGER
load to be lifted.
WARNING
Proceed as follows:
1. Carry out operation 90 100 22: Hood opening,

only removal (see page 2).
2. Carry out operation 90 100 84: Hood guard, only

removal (see page 4).
3. Disconnect the engine oil pressure sensor con-

nection (1). 7
4. Unscrew the speedometer/tachometer (2) con-

trol cable and the clamp (1).
8
5. Disconnect the two steering cylinder control
pipes (1).
9
6. Unscrew the clamp and remove the thermostart-

er piping (1).
10
7. Unscrew the brake fluid tank retaining bolts (2),
remove the tank and attach to the RH handrail (1).
11
8. Unscrew the service brakes control piping (1).
12
9. Disconnect the engine electric connection (1).
13
10. Disconnect the thermostarter connection (1).
14
11. Disconnect the hydrostatic steering oil supply
and discharge lines (1).
15
12. Disconnect the accelerator control cable (1) from
the control lever.
16
13. Disconnect the gear clutch control tie--rod (1).
17
14. Disconnect the rear transmission electrical sys-

tem electrical connection (1).
18
15. Connect the dashboard to a hoist, allow the hoist
to take the strain and unscrew the retaining bolts
(1).
19
16. Using the hoist, remove the dashboard (1).
17. To refit the dashboard, proceed as follows.
WARNING
-- Position and secure the dashboard.

-- Connect the rear transmission electrical connec-
tion.
-- Connect the gear clutch control tie--rod.
-- Connect the accelerator control cable. 20
-- Connect the hydrostatic steering supply and dis- -- Connect and secure the speedometer/tachome-
charge lines. ter control cable.
-- Connect the engine oil pressure sensor connec-
-- Connect the thermostarter and engine electrical
tion.
connections.
-- Carry out operation 90 100 84: Hood guard, only
-- Connect the service brakes control piping.
installation (see page 4).
-- Position and secure the oil fluid tank.
-- Carry out operation 90 100 22: Hood opening,
-- Connect and secure the thermostarter piping. only installation (see page 2).
-- Connect the steering cylinder control piping. -- Bleed the brakes (see section 33)
Op. 90 114 26
ROPS (Roll Over Protection Structure)
DANGER
load to be lifted.
WARNING
Proceed as follows:
1. Connect the rear ROPS to a hoist and allow the

hoist to take the strain.
21
2. Disconnect the electrical connections (1) of the

lights attached to the ROPS (on both sides).
3. Unscrew the mudguards retaining bolts (1) from

the ROPS (on both sides).
22
4. Extract the retaining bolt and remove the multi--
pole socket (1) and support bracket.
23
5. Unscrew the retaining bolt (1) that holds the lift le-
ver control panel to the ROPS.
24
6. Unscrew the retaining bolts that hold the ROPS
bar to the final drive casing and remove the lower
bracket (1) (on both sides).
25
7. Using the hoist, remove the ROPS (1).
8. To refit the ROPS, proceed as follows.
WARNING
-- Position the ROPS and secure by means of the

relative brackets and bolts.
-- Fit the lift lever control panel.
-- Position the multi--pole socket and attach the

ROPS to the mudguards.
-- Connect the electrical connections to the lights on

the ROPS.
26
-- Free the ROPS from the hoist.
Op. 90 116 10
RIGHT OR LEFT--HAND MUDGUARD
WARNING
RH mudguard
Proceed as follows:
1. Remove the Lift--O--Matic control cable from the

lever. 27
2. Unscrew the retaining bolts and remove the RH

mudguard (1).
3. To refit the RH mudguard proceed as follows.
WARNING
-- Position and secure the RH mudguard.
-- Connect the Lift--O--Matic control cable. 28
Op. 90 116 10
RIGHT OR LEFT--HAND MUDGUARD
WARNING
LH mudguard
1. Unscrew the retaining bolts and remove the LH

mudguard (1).
2. Extract the retaining bolt and remove the multi--

pole socket (1)and support bracket.
3. To refit the LH mudguard proceed as follows.
WARNING
-- Position the LH mudguard and the multi--pole

socket and secure. 30
Op. 90 116 24
REAR GUARD
Replacement
WARNING
Proceed as follows:
1. Carry out operation 90 116 10: Right or left--hand

mudguard, only removal (both mudguards, see
page 11).
2. Unscrew the PTO control lever knob. 31
3. Disconnect the lift control lever (2) drive rods.

4. Disconnect single pole connection (1).
32
5. Unscrew the retaining bolts and remove the tool
box (1), together with the relative support.
33
6. Remove the control valve tie--rod (1) from both

the external lever and the support bracket.
34
7. Unscrew the retaining bolt and remove the seat
(1).
35
8. Unscrew the retaining bolts and remove the gear
and range gear control levers (1 and 2).
9. Disconnect the differential lock control pedal (3)
from the tie rod.
36
10. Disconnect the parking brake tie--rod (1).
37
11. Unscrew the retaining bolts and remove the rear
guard (1).
12. To refit the rear guard proceed as follows.
WARNING
-- Position and secure the rear guard using the

bolts.
-- Connect the parking brake tie--rod.
-- Connect the differential lock control tie--rod.
-- Assemble and secure the gear and range gear 38
control levers.
-- Assemble and secure the seat.
-- Connect the control valves tie--rod.
-- Assemble and secure the tool box.
-- Connect the single pole socket connection.
-- Fit the lift control lever tie--rods.
-- Screw on the PTO control lever knob.
-- Carry out operation 90 116 10: Right or left--hand
mudguard, only installation (both mudguards,
see page 11).

New Holland Tn55 Tn65 Tn70 Tn75 Workshop Manual

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SECTION 00 -- GENERAL -- CHAPTER 1 1

ROTATING SHAFT SEALS

MOVING THE TRACTOR WITH THE BATTERY REMOVED

START UP HYDRAULIC SYSTEMS

Water and liquid Water and liquid SAE1941 ASTM

Crankcase sump: AMBRA NH Break-In API

Brake control circuit . . . . . . 0.7 (0.18) AMBRA NH Brake Oil

Rear transmission (bevel

AMBRA GR9 NH Super Premium

Section Description Page

Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated camshaft

-- start: before TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12o

-- end: after BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31o

-- start: before BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50o

-- end: after TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16o

Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.02 inches)

Valve clearance for normal running (engine cold):

-- inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 mm (0.01 ± 0.002 inches)

-- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 mm (0.01 ± 0.002 inches)

For further timing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 16

Turbocharger (model TN 70 and TN 75):

Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type with incorporated speed

-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 767

-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 766

-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 764--2

-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 764

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . counter--clockwise

Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2--3

BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500307714

-- Nozzle holder type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4791124

-- Nozzle type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 132S 1320 -- 99469341

Number of nozzle orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Diameter of nozzle orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 mm (0.01 inches)

Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 to 272 bar (3771.2 to 3945.2 psi)

Fuel delivery lines -- BOSCH pump

-- dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 x 1.75 x 540 mm (0.24 x 0.07 x 21.26 in.)

ASSEMBLY DATA CALIBRATION TEST CONDITIONS

2. ADVANCE REGULATOR STROKE

3. FUEL SUPPLY PUMP PRESSURE

4. FULL LOAD DELIVERY

5. SPREAD GOVERNOR AT IDLE SPEED

6. SPREAD GOVERNOR AT MAXIMUM SPEED

8. INJECTION ADVANCE PROGRESSION

9. TRANSFER PRESSURE PROGRESSION

11. DELIVERY PROGRESSION

12. ZERO CAPACITY (STOP)

13. DELIVERY CHECK AT IDLE SPEED

14. AUTOMATIC START SUPPLEMENT

BENCH TEST PERFORMANCE DATA

ASSEMBLY DATA CALIBRATION TEST CONDITIONS

2. ADVANCE REGULATOR STROKE

3. FUEL SUPPLY PUMP PRESSURE

4. FULL LOAD DELIVERY

5. SPREAD GOVERNOR AT IDLE SPEED

6. SPREAD GOVERNOR AT MAXIMUM SPEED

8. INJECTION ADVANCE PROGRESSION

9. TRANSFER PRESSURE PROGRESSION

11. DELIVERY PROGRESSION

12. ZERO CAPACITY (STOP)

13. DELIVERY CHECK AT IDLE SPEED

14. AUTOMATIC START SUPPLEMENT

BENCH TEST PERFORMANCE DATA

12. DELIVERY PROGRESSION

13. DELIVERY CHECK AT IDLE SPEED